Damping method including a face-centered cubic ferromagnetic damping material, and components having same

ABSTRACT

A method to increase the damping of a substrate using a face-centered cubic ferromagnetic damping material.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.15/268,748, filed on Sep. 19, 2016, which is a continuation of U.S.application Ser. No. 14/059,549, now U.S. Pat. No. 9,458,534, filed onOct. 22, 2013, the entire contents of which are hereby incorporated byreference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Part of the invention herein described was made in the course of orunder a contract with the U.S. Department of the Navy.

TECHNICAL FIELD

The present disclosure relates to coatings applied to a surface of asubstrate. More specifically, the present disclosure is directed to amethod to increase the high strain damping of a substrate using aface-centered cubic ferromagnetic damping coating to improve thedurability, reliability, safety, and performance of gas turbines, steamturbines, and other metallic articles which operate under cyclic loadingconditions.

BACKGROUND OF THE INVENTION

Engineering components, particularly rotating components such as turbinefan blades, compressor blades, impellers, blisks, and integrally bladedrotors (IBRs), commonly encounter vibrational stresses in operation.These vibrational stresses can fatigue the component and eventuallycause the component to fail. In order to prevent component failure,researchers have investigated a number of approaches for attenuating thevibrations that develop under cyclic loading. Such approaches haveincluded dry friction dampers, tuned-mass or particles, air cavities,shape memory alloys, viscoelastic dampers, and ceramic coatings. Anotherapproach that has been considered for vibration damping is theapplication of a thin coating of a ferromagnetic material on a surfaceof a substrate. Examples of ferromagnetic materials are Fe alloysincluding combinations of one or more Al, Mo and Mn and Co alloysincluding combinations of one or more Ni, Cr, Mn, and Si. In particular,Fe—Cr based ferromagnetic materials comprising about 16% (by weight)chromium (Cr), either about 1% to about 6% aluminum (Al) or about 1% toabout 4% molybdenum (Mo), and the balance iron (Fe), have been shown toexhibit high damping, as well as good mechanical strength and corrosionresistance. As a result, the ferromagnetic materials are consideredwell-suited for applications involving severe and hostile operatingconditions, such as those experienced by turbine components. There areseveral drawbacks to prevent application of ferromagnetic materials forvibration damping enhancement. These drawbacks include: (I)ferromagnetic damping may be constrained by residual stresses during thecoating processes; and (II) ferromagnetic damping is strain dependentand usually reaches to the maximum value at very low strain levels andquickly decays to low damping at high strain regions.

As mentioned, Fe—Cr based ferromagnetic materials have been shown topossess a high damping capacity. These ferromagnetic materials includemagnetic domains, which are separated by magnetic domain walls. When theferromagnetic material is exposed to external magnetic fields orstresses, the magnetic domain walls can move. When the movement of themagnetic domain walls is irreversible, a portion of the energy providedto the ferromagnetic material is dissipated as internal friction. Thisdamping mechanism is commonly referred to as magnetomechanical damping.Thus, high damping in ferromagnetic materials is achieved due to theirreversible movement of the magnetic domain walls. If movement of themagnetic domain walls is constrained or hindered, the ferromagneticmaterial will not exhibit any appreciable damping. Unfortunately,conventional coating processes may create large residual stresses thatact as obstacles to the movement of the magnetic domain walls. Forexample, in a conventional air plasma spray process, the residual stressis dominated by tensile quenching stresses; while in a conventional coldspray process, the residual stress is dominated by compressive peeningstresses. As a result, a ferromagnetic coating applied to a substrate byconventional coating processes will provide no significant damping. Inorder to free up the movement of the magnetic domain walls, the commoncourse of action is to subject the coated article to a high temperatureannealing process. For example, one commonly suggested process includesan annealing process in a high vacuum at temperatures between 900° C. to1200° C. for 6 hours. Such a high temperature annealing process is acritical drawback that has hindered the use of ferromagnetic materialsin real world applications. For example, high temperature annealing ofgeometrically complex structural components, such as gas turbine enginecomponents, can cause microstructural defects, decomposition, andprecipitation in component substrate materials. Further, such hightemperature annealing may warp or deform the structural componentrendering the component unfit for its intended use. Thus there is a needin the art for a process capable of depositing a coating comprising aferromagnetic damping material on a surface of a substrate withoutrequirement of high temperature heat treatment.

The dependency of the strain or stress amplitude and the dampingcapability (characterized as loss factory η or Q⁻¹) of ferromagneticmaterials have been carefully evaluated. A number of vibration modalanalyses/tests have been conducted on a flat polished beam specimen,made substantially entirely from the ferromagnetic material withcomposition contain of a mixture of Fe and Cr, and an active ingredientof Al or Mo. The weight ratios of Fe—Cr—Al or Mo are Fe—16% Cr—0% Al orMo to Fe—16% Cr—6% Al or Fe—16%—4% Mo. As shown in FIG. 6, high dampingcapability and the damping dependence of the applied strain was obtainedbased on the experimental data at the first bending mode of a beam madeentirely of the BCC Fe—Cr based ferromagnetic materials/alloys named as“low strain.” The frequency response results clearly show that thedamping capacity of the coating specimen improves as the forcingacceleration increases. However, the damping increases rapidly as theforcing accelerations increases and reaches a stationary value as themaximum strain of the beam approaching 80 to 100 micro-strains and thendecreases relatively quickly at higher strain regions. Fatigue failurein real turbine hardware is usually occurs under high strain or stressoperating conditions. Therefore, there is a need in the art for a newferromagnetic material capable of providing high damping at high strainregions. Thus there is a need in the art for a process capable ofdepositing a coating comprising a face-centered cubic ferromagneticdamping material on a surface of a substrate that exhibits a highdamping capacity, particularly at high strain levels, without having toundergo a high temperature annealing process.

SUMMARY OF THE INVENTION

In its most general configuration, the presently disclosed method forapplying a face-centered cubic ferromagnetic damping coating advancesthe state of the art with a variety of new capabilities and overcomesmany of the shortcomings of prior methods in new and novel ways. Themethod for applying a face-centered cubic ferromagnetic damping coatingovercomes the shortcomings and limitations of the prior art in any of anumber of generally effective configurations. The face-centered cubicferromagnetic damping coating is applied to a surface of a substratethat is selected from the group consisting of Co—Ni based face-centeredcubic compositions, Co—Mn based face-centered cubic compositions, andFe—Mn based face-centered cubic compositions. The face-centered cubicferromagnetic damping coating may be applied using several differentprocesses and application parameters that ensure the coating has lowresidual stress and possesses good damping properties in high strainregions. Such processes include, but are not limited to, high velocityoxygen fuel (HVOF) system embodiments, cold spray process embodiments,physical vapor deposition (PVD) process embodiments, and damping foilsystem embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

Without limiting the scope of the claimed method and associatedproducts, reference is now given to the drawings and figures:

FIG. 1 is a schematic of equipment applying a face-centered cubicferromagnetic damping coating on a surface of a substrate, not to scale;

FIG. 2 is a cross-sectional view of a substrate with a face-centeredcubic ferromagnetic damping coating applied to a surface thereof, not toscale;

FIG. 3 is a cross-sectional view of a substrate with a face-centeredcubic ferromagnetic damping coating applied to a surface thereof, not toscale;

FIG. 4 is a cross-sectional view of a substrate with a face-centeredcubic ferromagnetic damping coating applied to a surface thereof, not toscale;

FIG. 5 is a cross-sectional view of a substrate with a face-centeredcubic ferromagnetic damping coating applied to a surface thereof, not toscale;

FIG. 6 shows a graph of a test beam system loss factor versus max strainat the first bending mode for a body-centered cubic (BCC) ferromagneticmaterial test beam;

FIG. 7 shows a graph of a test beam system loss factor versus max strainat the first bending mode for a face-centered cubic (FCC) ferromagneticmaterial test beam;

FIGS. 8 & 9 show a graph of a coated beam system loss factor versus maxstrain at the fourth bending mode for several test specimens;

FIGS. 10 & 11 show a graph of a coated beam system loss factor versusmax strain at the third bending mode for several test specimens;

FIGS. 12 & 13 show a graph of a coated beam system loss factor versusmax strain at the second bending mode for several test specimens;

FIG. 14 shows a graph of a local loss factor versus local strain forseveral test specimens;

FIG. 15 shows a graph of a coated beam system loss factor versus maxstrain at the second bending mode for several test specimens;

FIG. 16 shows a graph of a coated beam system loss factor versus maxstrain at the third bending mode for several test specimens;

FIG. 17 shows a graph of a coated beam system loss factor versus maxstrain at the fourth bending mode for several test specimens;

FIG. 18 shows a graph of a coated beam system loss factor versus maxstrain at the third bending mode for several test specimens;

FIG. 19 shows a graph of a coated beam system loss factor versus maxstrain at the fourth bending mode for several test specimens;

FIGS. 20 & 21 show a graph of a coated beam system loss factor versusmax strain at the second bending mode for several test specimens;

FIG. 22 shows a graph of a coated beam system loss factor versus maxstrain at the third bending mode for several test specimens;

FIG. 23 shows a graph of a coated beam system loss factor versus maxstrain at the fourth bending mode for several test specimens;

FIG. 24 is a schematic of equipment applying a face-centered cubicferromagnetic damping coating on a surface of a substrate, not to scale;

FIG. 25 is a top plan view of a dimensioned coated test beam, not toscale;

FIG. 26 is a top plan view of a dimensioned cast test beam, not toscale;

FIG. 27 is a side elevation view of a dimensioned cast test beam, not toscale;

FIGS. 28 & 29 show a graph of a coated beam system loss factor versusmax strain at the second bending mode for several test specimens;

FIGS. 30 & 31 show a graph of a coated beam system loss factor versusmax strain at the third bending mode for several test specimens;

FIGS. 32 & 33 show a graph of a coated beam system loss factor versusmax strain at the second bending mode for several test specimens;

FIGS. 34 & 35 show a graph of a coated beam system loss factor versusmax strain at the third bending mode for several test specimens;

FIGS. 36 & 37 show a graph of a coated beam system loss factor versusmax strain at the second bending mode for several test specimens;

FIGS. 38 & 39 show a graph of a coated beam system loss factor versusmax strain at the third bending mode for several test specimens;

FIGS. 40 & 41 show a graph of a coated beam system loss factor versusmax strain at the second bending mode for several test specimens;

FIGS. 42 & 43 show a graph of a coated beam system loss factor versusmax strain at the third bending mode for several test specimens;

FIG. 44 is an isometric view of an ingot, not to scale;

FIG. 45 is an isometric view of a portion of a foil rolling apparatus,not to scale;

FIG. 46 is an isometric view of a foil, not to scale;

FIG. 47A is cross-sectional view of an ingot, not to scale;

FIG. 47B is cross-sectional view of a foil, not to scale;

FIG. 48A is top plan view of an ingot, not to scale;

FIG. 48B is top plan view of a foil, not to scale;

FIG. 49A is top plan view of a foil, not to scale;

FIG. 49B is top plan view of a foil, not to scale;

FIG. 50A is cross-sectional view of an ingot, not to scale;

FIG. 50B is cross-sectional view of a foil, not to scale;

FIG. 51A is top plan view of an ingot, not to scale; and

FIG. 51B is top plan view of a foil, not to scale.

These drawings are provided to assist in the understanding of exemplaryembodiments as described in more detail below and should not beconstrued as unduly limiting. In particular, the relative spacing,positioning, and dimensions of the various elements are not drawn toscale and may have been exaggerated, reduced or otherwise modified forthe purpose of improved clarity. Those of ordinary skill in the art willalso appreciate that a range of alternative configurations have beenomitted simply to improve the clarity and reduce the number of drawings.

DETAILED DESCRIPTION OF THE INVENTION

The presently disclosed method for applying a high strain dampingcoating enables a significant advance in the state of the art. Thepreferred embodiments of the method accomplish this by new and novelarrangements of elements and steps that are configured in unique andnovel ways and which demonstrate previously unavailable but preferredand desirable capabilities. The description set forth below inconnection with the drawings is intended merely as a description of theembodiments of the claimed method, and is not intended to represent theonly form in which the method may be constructed, carried out, orutilized. The description sets forth the designs, functions, means, andmethods of implementing the method in connection with the illustratedembodiments. It is to be understood, however, that the same orequivalent functions and features may be accomplished by differentembodiments that are also intended to be encompassed within the spiritand scope of the claimed method.

With reference now to FIG. 2, a cross-sectional view of a substrate (20)having a face-centered cubic ferromagnetic damping coating (10) appliedto a surface (24) of the substrate (20) is shown. The face-centeredcubic damping material, powder in some embodiments, is selected from thegroup consisting of Co—Ni based face-centered cubic compositions, Co—Mnbased face-centered cubic compositions, and Fe—Mn based face-centeredcubic compositions. In one embodiment, the face-centered cubic (FCC)ferromagnetic damping material utilized to create the face-centeredcubic ferromagnetic damping coating (10) comprises a Co—Ni basedface-centered cubic ferromagnetic damping material. In one embodimentthe face-centered cubic damping material includes 20-40 weight % nickel.In a further embodiment the face-centered cubic damping materialincludes about 22% (by weight) to about 40% of nickel (Ni), with amajority of the balance being cobalt (Co). One particular Co—Mn basedface-centered cubic composition includes at least 15-26 weight %manganese. Further, a Fe—Mn based face-centered cubic compositionincludes at least 13-25 weight % manganese. In a further embodiment theFe—Mn face-centered cubic damping material includes at least 15-22weight % manganese. Further Co—Ni based face-centered cubicferromagnetic damping material embodiments include 0.1-0.5 weight %aluminum to aid in the manufacturability of an ingot, depending on theapplication process, thereby reducing porosity of the face-centeredcubic ferromagnetic damping coating (10); and even further embodimentsmay include 0.5-1.5 weight % chromium to further reduce porosity.

With reference now to FIG. 1, an embodiment of a method for applying alow residual stress high strain face-centered cubic ferromagneticdamping coating (10) to a surface (24) of a substrate (20) will bedescribed. As seen in FIG. 1, the components of a cold spray processgenerally include a gas supply (40) that is routed to a spray gun (60)and through a powder feed system (90) containing the face-centered cubicdamping powder. The gas supply (40) that is routed directly to the spraygun (60) may pass through a heater (50). The powder feed system (90) isalso fed to the spray gun (60) where it mixes prior to being acceleratedin a nozzle (80). The gas and powder mixture are discharged from thespray gun (60) at a very high velocity, generally greater than 300meters per second, and often supersonic.

In another embodiment the face-centered cubic damping powder is heatedbefore it is fed into the spray gun (60). In this embodiment theface-centered cubic damping powder is heated to a temperature that is atleast 5% less than the melting point of any component of the dampingpowder. In a further heated powder embodiment the face-centered cubicdamping powder is heated to a temperature of at least 400 degreesCelsius. The face-centered cubic damping powder may be heated via adiode laser or high temp gas heater that is highly controlled so thatthe face-centered cubic damping powder is hot but not molten so thatlower particle velocities may be used, thereby reducing the peeningcompressive stress and producing very low residual stress inface-centered cubic ferromagnetic damping coating (10).

In one embodiment the spray gun (60) may be from the CGTKINETIKS—4000/34-x cold spray system, which uses the energy stored inhigh press compressed gas, generally nitrogen or helium, to propel theface-centered cubic damping powder at very high velocities, generally300-1500 meters per second. Compressed gas is fed into the gun via aheating unit through a nozzle at very high speed. The face-centeredcubic damping powder is accelerated to a predetermined velocity where onimpact with substrate it deforms and bonds to form a dense face-centeredcubic ferromagnetic damping coating (10). The temperature of theface-centered cubic damping powder increases through the process, whichin some embodiments includes a step of heating the powder, however inthe cold spray process embodiment the powder always remains in the solidstate, hence the bulk reaction on impact is solid state only and thecoatings tend to be stressed and deformed under compression.

In one embodiment the low stress face-centered cubic ferromagneticdamping coating (10) is achieved by utilizing a very low applicationvelocity in the range of approximately 300 meters per second to 750meters per second, while utilizing a spray gun (60) temperature of400-700 degrees Celsius. The high strain face-centered cubic dampingpowder of the present invention require tight control of theseparameters because the associated high strength values of the highstrain face-centered cubic damping powder can quickly foul the spray gun(60) if it becomes too soft as a result of overheating.

Unique process parameters are used to apply the face-centered cubicferromagnetic damping coating (10) and achieve low residual stress andproduce a damping coating (10) having relatively large grain sizes,which enhances the high strain damping performance. Conventional coldspray and HVOF process parameters are designed to achieve good bondstrength and density, and would result in residual stress levels andsmall coating grain size that negatively impact the dampingcapabilities, particularly high strain damping. Conventional wisdomgenerally utilizes high velocity application of the face-centered cubicferromagnetic damping powder, often indicated by a high gas pressure ofgreater than 40 Bar, applied very close to the substrate, generally aspray distance of less than 20 mm, with a gun temperature of 400-500° C.The present relationship of process parameters results in very lowresidual compressive stress and large coating grain size, therebyresulting in improved damping capabilities, particularly at high strainlevels. A preferred relationship between spray gun temperature, gaspressure, gas flow rate, powder feed rate, powder size, and spraydistance has been discovered. In one particular embodiment a preferredcoated substrate (100) is produced when the face-centered cubicferromagnetic damping powder is delivered within the spray parametersand ranges identified in Table 1 below.

TABLE 1 # PARAMETER VALUE 1 Process Gas Nitrogen or Helium 2 GunTemperature (° C.) 400-700 3 Gas Pressure (Bars) 20-45 4 Carrier Gas(Nitrogen) Flow Rate 2.0-3.0 (m3/Hr) 5 Powder Feed Rate (RPM) 1.5-3.0 6Powder size (μm, microns)  5-100 7 Spray distance (mm) 10-40

In a preferred embodiment the process parameter relationships produce aparticularly low residual stress and large grain size by utilizing a lowvelocity characterized by a gas pressure of less than 30 Bar incombination with a relatively high gun temperature of at least 500° C.and a large spray distance of at least 25 mm. In an even furtherembodiment preferred high strain damping was achieved when the processparameter relationships produce a particularly low residual stress andlarge grain size by utilizing a gas pressure of less than 25 Bar incombination with a gun temperature of at least 600° C. and a spraydistance of at least 35 mm. Further, another embodiment may depositmultiple layers face-centered cubic ferromagnetic damping coating (10)with each layer being applied using different process parameters toachieve different grain sizes and/or damping properties. For example afirst layer may utilize process parameter relationships produce aparticularly low residual stress and large grain size by utilizing a lowvelocity characterized by a first gas pressure and a first guntemperature, and a second layer may utilize process parameterrelationships produce a different grain size by utilizing a second gaspressure and a second gun temperature, wherein the first gas pressureand the second gas pressure differ by at least 15% and the first guntemperature and the second gun temperature differ by at least 20%.

In addition to the cold spray process embodiment just discussed, anotherembodiment utilizes a high velocity oxygen fuel (HVOF) system to applythe low residual stress high strain face-centered cubic ferromagneticdamping coating (10) to a surface (24) of a substrate (20). In thisembodiment, as seen in FIG. 24, the HVOF method utilizes a spray torch(30) for applying the face-centered cubic damping powder to the surface(24) of the substrate (20). The spray torch (30) preferably comprises ahigh velocity oxygen fuel (HVOF) type torch, such as those used inconnection with the Praxair-Tafa JP-5000 HVOF spray system and Jet Kotespray systems. In a HVOF spray system embodiment, a mixture of fuel (F)and oxygen (O) is fed to the spray torch (30) where the mixture iscombusted. The face-centered cubic damping powder (P) is fed to thespray torch (30) where the powder (P) particles are entrained by thecombustion gases and undergo heating and acceleration as they travelthrough and exit the spray torch (30). The spray torch (30) may besupplied with cooling water (CW) to help control the temperature of theprocess.

In one HVOF embodiment, the method includes heating the face-centeredcubic damping coating powder so that it is at least partially molten.The heating step may be accomplished in the spray torch (30) from thehot combustion gases as described above. To ensure that theface-centered cubic damping coating powder is at least partially molten,it is preferable to heat the face-centered cubic damping coating powderto, or near, its melting point. Next, the at least partially moltenface-centered cubic damping coating powder is directed at a surface (24)of the substrate (20) at a HVOF application velocity. The HVOFapplication velocity is such that the at least partially moltenface-centered cubic damping coating powder adheres to the surface (24)of the substrate (20). After the at least partially molten face-centeredcubic damping coating powder adheres to the surface (24) of thesubstrate (20), it cools to solidification within a solidificationperiod to create the face-centered cubic ferromagnetic damping coating(10) on the surface (24) of the substrate (20), thus forming a coatedsubstrate (100). The solidification period is relatively rapid,generally less than a few seconds.

In addition to the high velocity oxygen fuel (HVOF) system and the coldspray process embodiments just discussed, another embodiment utilizes anelectron beam physical vapor deposition (EB-PVD) process to apply thelow residual stress high strain face-centered cubic ferromagneticdamping coating (10) to a surface (24) of a substrate (20). As opposedto the HVOF process and the cold spray process that apply aface-centered cubic damping coating powder at significant velocity tothe substrate, one skilled in the art will recognize that the EB-PVDprocess utilizes focused high-energy electron beams generated fromelectron guns to melt and evaporate ingots of the face-centered cubicdamping coating material as well as to preheat the substrate inside avacuum chamber. Thus, all the disclosure herein with respect thecomposition of the face-centered cubic damping coating powder is alsoapplicable to an ingot, or ingots, of face-centered cubic dampingcoating material used in the EB-PVD process. Due to the change inpressure, the vapor rises and traverses the vacuum chamber where itcondenses on the substrate to form the face-centered cubic ferromagneticdamping coating (10). To obtain more uniform coatings, the sample isoften rotated during the coating process. In one particular embodimentthe substrate (20) is heated and maintained at a temperature of 50° C.to 350° C. to ensure good fatigue performance.

When discussing electron beam (EB) evaporation techniques for compounds,one skilled in the art will know that there are three main methods usedto obtain the proper stoichiometry or phase of the compound; namely,direct evaporation, reactive ion beam evaporation, and co-evaporation.Further, references used herein to the ED-PVD process includederivatives of the EB-PVD process such as ion plating and activatedreactive evaporation, as well as ion beam assisted deposition (IBAD),which is often used in conjunction with one of the conventionalevaporation or PVD techniques to change the properties andmicrostructure of the depositing coating. In one embodiment the state ofthe internal stresses developed in the coating can be changed fromtensile to compressive stress by the forcible injection of high-energyatoms (i.e., ion implantation). Thus, the ability to control the stresslevel is an additional feature of the IBAD. Ion bombardment duringdeposition has a tendency to reduce the tensile stress and often changesthe intrinsic stress from tensile to compressive.

In another embodiment ion beam assisted deposition (IBAD) is used toincrease the hardness of the coated substrate (100). The increase inhardness is obtained by increasing the density, decreasing grain size,changing stress state, and/or controlling the crystallographic textureof the coating. A further embodiment includes ion implantation, which isa higher degree of energy than IBAD, of Ni and Ti to increase thehardness of the coated substrate (100).

In one embodiment the EB-PVD process is preceded by a bombardment of thesubstrate surface prior to deposition (i.e., sputter cleaning) topromote better adhesion of the face-centered cubic damping coating. Thissputter cleaning serves to remove adsorbed hydrocarbons and watermolecules, and increase the density of nucleation sites forcondensation.

In addition to the high velocity oxygen fuel (HVOF) system, the coldspray process embodiments, and the electron beam physical vapordeposition (EB-PVD) processes just discussed, the low residual stresshigh strain face-centered cubic ferromagnetic damping coating (10) maybe applied to a surface (24) of a substrate (20) in the form of a foil(600), as illustrated in FIGS. 44-51. Such foil based embodimentsprovide is low residual stress high strain face-centered cubicferromagnetic damping foil systems that in some embodiments are attachedto the substrate (20) using low temperature application methods inconjunction with a foil manufacturing procedure for achieve highdamping, erosion resistance, and corrosion resistance. The presentinvention includes developing new ferromagnetic alloy foils to enlargehigh damping effective regions to high strain levels. Embodimentsprovide exceptional damping and erosion-resistance capability with anintegrated design of multi-functional and multi-layered foil systems.One embodiment includes methods for: (1) designing new ferromagneticalloys (named high strain damping material) with face-centered cubic(FCC) structure with 4 easy magnetization axis to enlarge high dampingeffective regions to high strain levels which usually occurs in realengine hardware, (2) applying a low residual stress damping coatingadvances the state of the art with a variety of new capabilities andovercomes many of the shortcomings of prior methods in new and novelways, (3) developing an integrated design of multiples coatingconfiguration to achieve high damping at all strain levels, and (4)constructing an erosion-resistant damping coating system byincorporating hard carbides (like SiC) in the damping coating depositionprocesses for achieving high erosion and wear resistance along withincreased hardness, improved corrosion resistance, and high temperatureoxidation resistance.

In one embodiment the method of increasing the damping of a substrateincludes the steps of a) creating a face-centered cubic damping materialingot (500) comprising a face-centered cubic damping material, andhaving a ingot length (510), ingot width (520), and ingot thickness(530), as seen in FIG. 44; b) rolling the face-centered cubic dampingmaterial ingot (500), as seen in FIG. 45, to create a face-centeredcubic damping material foil (600) having a foil grain size, foil length(610), foil width (620), foil thickness (630), and hardness, as seen inFIG. 46; c) applying an erosion-resistant coating onto at least aportion of the face-centered cubic damping material foil, wherein theerosion-resistant coating increases the hardness to a Vickers hardnessof at least 350 HV; and d) applying a portion of the erosion-resistantcoated FCC damping material foil to the substrate. It should be notedthat all of the disclosure contained herein with respect to theface-centered cubic ferromagnetic damping coating (10), also identifiedas element #14 in the illustrated multi-layer embodiments such as FIG.3, applies equally to the face-centered cubic damping material foil(600), with the obvious exception of the method of manufacture.

The step of applying the erosion-resistant coating onto at least aportion of the face-centered cubic damping material foil may beperformed utilizing the disclosed high velocity oxygen fuel (HVOF)system embodiments, cold spray process embodiments, and physical vapordeposition (PVD) process embodiments. In one particular PVD embodimentthe step of applying the erosion-resistant coating onto at least aportion of the face-centered cubic damping material foil (600) includesthe steps of: (i) creating an erosion-resistant material ingot; (ii)placing the erosion-resistant material ingot and the face-centered cubicdamping material foil in a vacuum chamber; (iii) heating theface-centered cubic damping material foil to an erosion-resistant layerapplication temperature; (iv) forming an erosion-resistant layer vaporfrom the erosion-resistant material ingot within the vacuum chamber; and(v) condensing the erosion-resistant layer vapor on at least a portionof the face-centered cubic damping material foil (600) to create theerosion-resistant coating of an erosion-resistant coated FCC dampingmaterial foil, wherein the erosion-resistant coating has anerosion-resistant coating thickness and an erosion-resistant coatinggrain size different than the foil grain size. In one particularembodiment the erosion-resistant coating thickness is less than 0.006″and a PVD application process is used; while in another embodiment theerosion-resistant coating thickness is at least 0.006″ and a HVOFapplication process is used. Regardless of the application process,applying the erosion-resistant coating to a flat face-centered cubicdamping material foil, as opposed to the complex geometry of a commonsubstrate, namely a turbine component, provides for increasedproduction, higher quality, and tighter tolerances. In fact, in oneembodiment the rolling step produces the face-centered cubic dampingmaterial foil with a surface roughness of less than 0.635 μm for Rawithout requiring a polishing step, yet another production savings;while in an even further embodiment the rolling step produces theface-centered cubic damping material foil with a surface roughness of nomore than 0.400 μm for Ra without requiring a polishing step. In still afurther embodiment the erosion-resistant coating thickness is less than0.004″, while in yet another embodiment the erosion-resistant coatingthickness is less than 0.0025.″ In yet another embodiment theerosion-resistant coating grain size differs from the foil grain size byat least 2%, and by at least 4% in a further embodiment, and by at least6% in still a further embodiment.

It should be noted that the disclosed erosion-resistant coating may bean erosion-resistant damping coating (16), such as that illustrated inFIG. 3 and disclosed later in great detail. Such an erosion-resistantdamping coating may achieve high erosion and wear resistance along withincreased stiffness, strength, hardness, improved corrosion resistance,and high temperature oxidation resistance. In some embodiment hard metalcarbides such as tungsten carbine and boron carbide may be incorporated.Further, in one embodiment the step of applying the erosion-resistantcoating, or erosion-resistant damping coating, onto at least a portionof the face-centered cubic damping material foil is followed by theapplication of a metallic damping layer, which may be a face-centeredcubic damping layer, either of which may be an interlayer sandwichedbetween two erosion-resistant coatings, erosion-resistant dampingcoatings, or a combination thereof. For example, one embodiment theface-centered cubic damping material foil at least partially covered bya includes a first erosion-resistant coating layer, which is then atleast partially covered by a first metallic damping interlayer, whichmay be a face-centered cubic damping layer, which is then at leastpartially covered by a first erosion-resistant coating layer. Theefficiencies afforded by coating a flat face-centered cubic dampingmaterial foil in a controlled environment allow for the incorporation ofmultiple erosion-resistant coating layers and multiple metallic dampinginterlayers to achieve a foil with unique damping and erosion resistantproperties. In fact, in one embodiment has three erosion-resistantcoating layers separated by two metallic damping interlayers, allapplied via a PVD method, with at least two out of the five layers beingapplied at different temperatures to obtain different grain sizes andmaterial properties, whether they be damping properties and/or erosionresistance properties. Another embodiment has five erosion-resistantcoating layers separated by three metallic damping interlayers, with atleast three out of the eight layers being applied at differenttemperatures to obtain different grain sizes and material properties. Inanother embodiment the combined total thickness of the erosion-resistantcoating layers is greater than the foil thickness (630). The combinationof a hard erosion-resistant coating, or erosion-resistant dampingcoating (16), and a soft interior face-centered cubic ferromagneticdamping foil (600) provides the ability to withstand very high stressand fatigue which therefore can act as a damage barrier to preventcracks from penetrated into the substrate and to arrest cracks initiatedfrom the substrate. Additionally, the softer face-centered cubicferromagnetic damping foil (600) layer significantly suppresses bladevibration and improves interface adhesion.

Production of the face-centered cubic damping material ingot (500) androlling the face-centered cubic damping material ingot (500) to create aface-centered cubic damping material foil (600) that is then coated toachieve the desired properties is complex and several criticalrelationships have been discovered. In one embodiment the foil length(610) is at least 2 times the ingot length (510), while in anotherembodiment the foil length (610) is at least 4 times the ingot length(510), and in a further embodiment the foil length (610) is at least 6times the ingot length (510), and in still a final embodiment the foillength (610) is at least 8 times the ingot length (510). Unlikeconventional foil production goals, namely producing as much foil aspossible from a single ingot, further embodiments introduce an upper capon the range to achieve preferential properties; this in one embodimentthe foil length (610) is less than 80 times the ingot length (510), andless than 60 times the ingot length (510) in another embodiment, andless than 50 times the ingot length (510) in a still further embodiment.Similarly with the foil thickness (630), the relationship of foilthickness (630) to ingot thickness (530), as well as the erosion-coatingthickness to the foil thickness (630), are significant and are notmerely relationships associated with maximizing production but again areessential for performance, manufacturability, and durability. Forinstance, in one embodiment the foil thickness (630) is less than 6% ofthe ingot thickness (530); while in another embodiment the foilthickness (630) is less than 4% of the ingot thickness (530); and thefoil thickness (630) is less than 2.5% of the ingot thickness (530) instill a further embodiment. Still further embodiments recognize thefloor needed at the opposite end of the range to ensure performance,durability, workability, and the ability to accommodate engineereddamping voids; as such in one embodiment the foil thickness is at least0.25% of the ingot thickness, while in another embodiment it is at least0.5% of the ingot thickness, and in still a further embodiment it is atleast 0.75% of the ingot thickness. Similarly, in one embodiment theerosion-resistant coating thickness is at least 20% of the foilthickness (630), while in another embodiment it is at least 35% of thefoil thickness (630), and in still yet a further embodiment it is atleast 50% of the foil thickness (630). Still further embodimentsrecognize a ceiling needed at the opposite end of the range to ensureperformance, durability, and workability; as such in one embodiment theerosion-resistant coating thickness is no more than 125% of the foilthickness (630), while in another embodiment it is no more than 110% ofthe foil thickness (630), and in still a further embodiment it is nomore than 95% of the foil thickness (630). In some mobile turbineapplications the ingot thickness (530) is 0.25″ or less, and the foilthickness (630) is 0.005″ or less; while in a further embodiment theingot thickness (530) is 0.15″ or less, and the foil thickness (630) is0.003″ or less; and in yet another embodiment the ingot thickness (530)is 0.125″ or less, and the foil thickness (630) is 0.002″ or less. Inother embodiments directed to much larger stationary turbine componentsthe foil thickness (630) is 0.250″ or less, and 0.200″ or less inanother embodiment, and 0.150″ or less in still another embodiment. Oneskilled in the art will recognize the many techniques that may be usedto apply the erosion-resistant coated FCC damping material foil to thesubstrate including, but not limited to, high-temperature adhesives,brazing, diffusion bonding, and welding, just to name a few.

In a series of embodiments improved performance is obtained when thestep of creating the face-centered cubic damping material ingot includesthe use of an additive manufacturing process. The Industrial Revolutionin the 1760's and ushered in a new era of products and manufacturingtechniques. With each passing decade manufacturing processes wouldevolve and improve manufacturing efficiency. As such, more and moregoods became accessible to end consumers with an ever decreasing cost.However, until recently most parts were fabricated by casting, molding,or subtractive manufacturing where material is removed by machining. Arelatively new process called additive manufacturing allows parts to befabricated by fusing layer upon layer of material in predefined shapesuntil the part is complete. Additive manufacturing can be used to makeparts out of metal, plastic, concrete, cermet, ceramic material,biological material, and many other materials. Currently, there areseven main categories of additive manufacturing: VATPhotopolymerisation; Material Jetting; Binder Jetting; MaterialExtrusion; Powder Bed Fusion; Sheet Lamination; and Directed EnergyDeposition. VAT photopolymerisation is an additive manufacturing processthat uses a vat of liquid photopolymer resin. An ultraviolet (UV) lightpolymerizes the photopolymer resin for a defined pattern of a layer,after which a platform moves a platform supporting the object being madedownwards. Next, another layer of resin with a defined pattern ispolymerized on the surface of the previous layer. The process repeatsuntil the object has been completed. Material jetting is an additivemanufacturing process that lays down layers by spraying or drop by dropin a fashion that is similar to how ink jet printers applies ink topaper. In this process the material deposition model moves horizontallyacross a build platform while the layer is being laid out. Binderjetting is an additive manufacturing process that uses a liquid binderand a powder based material. A material deposition head depositsalternating layers of binding material and build material horizontallyin the x and y axis of the support platform. In the material extrusionprocess, build material is heated as it passes through a materialdeposition head nozzle and then layer by layer it is deposited tofabricate a part. In some embodiments, the material deposition headmoves only in a horizontal fashion and a support platform moves up anddown vertically after each new layer is deposited. In other embodimentsthe material deposition head moves in the x, y, and z axis where thesupport platform remains stationary. The powder bed fusion process usesthe following fabrication methods: direct metal laser sintering (DMLS),electron beam melting (EBM), and selective heat sintering (SHS). Directmetal laser sintering (DMLS) also known as selective laser melting(SLM), and selective laser sintering (SLS) uses a laser to metalpowdered metal layer by layer to form a three dimensional metal part. Inoperation a layer of powdered metal is applied to a support platform. Alaser then melts the powder to a pattern defined by computer program.After the layer has been completed, a new layer of powdered metal isapplied and the process repeats itself until the part is completed.Electron beam melting uses an electron beam instead of a laser to meltthe powdered metal, but the rest of the process is the same. Theselective heat sintering method applies heat to layers of powderedthermoplastic by a thermal print head, thereby fusing the plasticaccording to the computer software. After a layer is completed, poweredthermoplastic is applied to the previous completed layer and the processrepeats until the part is completed. The sheet lamination process usessheets or ribbons of metal that is either adhesively or welded, oftenultrasonically, together. With this process, build material ispositioned on a cutting platform. Next, additional build material iswelded or glued in place, upon the previous layer. The layering processaccommodates complex internal structures, channels, and void,particularly when combined with intermediate subtractive manufacturingprocesses such as a laser, knife, or mill removes desired material fromthe structure or individual layer; after which, the process repeatsuntil the desired part, in this case ingot, is completed. Lastly, thedirected energy deposition process creates parts by melting buildmaterial while it is being deposited. It is commonly used with ceramics,polymers, and metal composites. Unlike the powder bed fusion processwhere the build material is a powder deposited on the part, the directedenergy deposition process deposits the build material directly at thepoint where a laser or electron beam is heating the part. Individuallayers are built up and the process is repeated until the part iscompleted.

As seen in the sections of FIGS. 47A and 47B, in one embodiment theadditive manufacturing process forms at least one closed internal void(700) within the face-centered cubic damping material ingot (500),wherein the void (700) has an initial void volume, an initial length(710 i), an initial void width (720 i), and an initial void height (730i), and the rolling process of creating the face-centered cubic dampingmaterial foil (600) deforms at least one aspect of the void producing afinal void volume, a final void length (710 f), a final void width (720f), and a final void height (730 f), wherein (a) the final void length(710 f) is at least 2 times the initial void length (710 i), (b) thefinal void height (730 f) is no more than 6% of the initial void height(730 i), and (c) the initial void height (730 i) is at least 20% of theerosion-resistant coating thickness. In a further embodiment the finalvoid length (710 f) is at least 4 times the initial void length (710 i),the final void height (730 f) is at least 0.5% of the initial voidheight (730 i), the initial void height (730 i) is 50-5000% of theerosion-resistant coating thickness, and the final void volume is atleast 10% less than the initial void volume. In another embodiment theinitial void height (730 i) is 50-400% of the erosion-resistant coatingthickness, which is more common for components of mobile turbines, andin still a further embodiment the initial void height (730 i) is 50-200%of the erosion-resistant coating thickness. References to the voidlength, width, and height, whether initial or final, refer to themaximum dimension measured in the illustrated X, Y, and Z dimensions,when sectioned in ingot form or foil form.

In another embodiment the additive manufacturing process is performed ina sealed environment containing a gas, and the at least one closedinternal void (700) within the face-centered cubic damping materialingot (500) contains the gas at an initial pressure; wherein the rollingprocess of creating the face-centered cubic damping material foil (600)deforms at least one aspect of the void (700) producing the final voidvolume containing the gas at a final pressure that is different from theinitial pressure. In one particular embodiment the final pressure is atleast 10% greater than the initial pressure, while in another embodimentit is at least 20% greater, and is at least 30% greater in an evenfurther embodiment. Another series of embodiments recognizes that aceiling on the pressure range is necessary to ensure efficientmanufacturing without excessive foil blow-outs, and durability; thus inone embodiment the final pressure is no more than 100% greater than theinitial pressure, and is no more than 80% in another embodiment, and nomore than 60% in still another embodiment.

As illustrated in FIGS. 48A and 48B, the ingot (500) and the foil (600)may include multiple voids (700, 800, 900) of varying sizes andprofiles. All of the disclosure for the initial void (700) appliesequally to the second void (800), the third void (900), and any furthervoids. Thus, the second closed internal void (800) within theface-centered cubic damping material ingot (500) has an initial secondvoid volume, an initial second void length (810 i), an initial secondvoid width (820 i), and an initial second void height (830 i), and therolling process of creating the face-centered cubic damping materialfoil (600) deforms at least one aspect of the second void producing afinal second void volume, a final second void length (810 f), a finalsecond void width (820 f), and a final second void height (830 f).Likewise, the third closed internal void (900) within the face-centeredcubic damping material ingot (500) has an initial third void volume, aninitial third void length (910 i), an initial third void width (920 i),and an initial third void height (930 i), and the rolling process ofcreating the face-centered cubic damping material foil (600) deforms atleast one aspect of the third void producing a final third void volume,a final third void length (910 f), a final third void width (920 f), anda final third void height (930 f). One particular embodiment has atleast a first, second, and third voids (700, 800, 900) and the volume ofeach void is different to achieve variable damping properties across thefoil; in fact, in a further embodiment the volume of each void varies byat least 25% from the volume of the lowest volume void, while in yetanother embodiment the void having the middle volume has a volume thatis at least 50% greater than the volume of the smallest void, while alsobeing at least 25% less than the volume of the largest void. Further,the ingot (500) has an ingot volume, and in one embodiment the totalvolume of all of the voids is at least 1% of the ingot volume, and is atleast 3% of the ingot volume in another embodiment, and at least 6% ofthe ingot volume in still a further embodiment. A still further seriesof embodiments recognizes the diminishing performance returns balancedwith manufacturability and durability and therefore introduce a ceilingon the range with one embodiment having the total volume of all of thevoids being no more than 75% of the ingot volume, and no more than 50%in another embodiment, and no more than 25% in still a furtherembodiment.

Just as the prior differences in void volume provide variable dampingproperties across the X and/or Y direction of the foil (600), so toowill varying a cross-sectional profile within a void. Thus, in someembodiments the void, or voids, may have constant cross-sectionalprofiles in one or more of the X, Y, and/or Z planes; however in otherembodiments they may have varying cross-sectional profiles in one ormore of the X, Y, and/or Z planes. For example, the third void (900) inFIGS. 48A and 48B, and all of the voids (700, 800, 900) in FIGS. 51A and51B clearly illustrate varying cross-sectional profiles in at least oneplane, as such the damping attributes can vary depending on the locationin the foil (600). While the shapes of the voids (700, 800, 900) inFIGS. 51A and 51B illustrate sharp intersections, the preferredconfiguration has smooth continuous surfaces having local radiuses ofcurvature of at least 0.5 micron and free of sharp corners and stressriser step discontinuities; thus the figures are intended to conciselyillustrate the variable cross-sectional area concept. For instance, whenanalyzing a void in the ingot, create five vertical sections in the Y-Zplane with the first plane passing through the centroid, the second andthird planes on opposite sides of the first plane and offset from thefirst plane a distance equal to 15% of the initial void length (710),and the fourth and fifth planes on opposite sides of the first plane andoffset from the first plane a distance equal to 30% of the initial voidlength (710). Likewise the same process may be followed to create 5vertical planes in the X-Z plane and utilizing the initial void width(720). Then the cross-sectional area of the void may be determined ineach of the 5 vertical planes, and an average cross-sectional areacalculated. One embodiment incorporates a variable void in which thecross-sectional area for at least two of the five vertical planes variesfrom the average cross-sectional area by at least 10% of the averagecross-sectional area; while in a further embodiment they vary by atleast 20% of the average cross-sectional area; and in yet a furtherembodiment they vary by at least 30% of the average cross-sectionalarea; any of which results in significant variation of the dampingproperties at different point in the foil (600), which is very desirablefor many applications.

In one embodiment the step of applying a portion of theerosion-resistant coated FCC damping material foil (600) to thesubstrate further including the step of first cutting anerosion-resistant coated FCC damping material foil pattern (1100) fromthe erosion-resistant coated FCC damping material foil (600). As seen inFIGS. 49A and 49B, the erosion-resistant coated FCC damping materialfoil pattern (1100) has a pattern perimeter (1110), which in someembodiments traverses across at least a portion of a void (700), ormultiple voids. The region that the pattern perimeter (1110) is incontact with the void (700) is a void interacting perimeter portion(1120), as seen in two locations along the pattern perimeter (1110) inFIG. 49A. The void (700) must be sealed at the void interactingperimeter portions (1120) so that the pattern (1100) may be removed fromthe foil (600) without the gas escaping the void (700). Therefore, afurther embodiment includes the step of creating a perimeter seal (1130)around the void interacting perimeter portions (1120), thereby allowingthe pattern (1100) to be cut and removed with the void (700) intact andretaining the gas. The perimeter seal (1130) may be created prior to thecutting process or may be incorporated with the cutting process.

The size and configuration of the void (700), or voids, significantlyinfluences the damping properties of the foil (600). In one embodimentthe initial void length (710 i), the initial void width (720 i), and theinitial void height (730 i) of the closed internal void (700) are eachless than 250 micron, while being less than 200 micron in anotherembodiment, and less than 150 micron in still a further embodiment, andless than 100 micron in yet another embodiment. In one particularembodiment each of the initial void length (710 i), the initial voidwidth (720 i), and the initial void height (730 i) are less than 50micron. Preferably the closed internal void (700) is formed of smoothcontinuous surfaces having local radiuses of curvature of at least 0.5micron and is free of stress riser step discontinuities. Such smoothsurfaces and curvature are necessary to reduce the likelihood of highstress areas once the rolling process takes place. In one particularembodiment the closed internal void (700) has an initial shape, in theingot (500), of a sphere, however other shapes including, but notlimited to, rectangular prism, cube, triangular prism, octagonal prism,triangular pyramid, square pyramid, cylinder, cones, ellipsoids,spheroids (oblate and prolate), and even a torus, may be incorporated.

As seen in FIGS. 50A and 50B, in some embodiments the closed internalvoid (700) includes a friction damping promoting region (1000), andwherein the rolling step deforms a portion of the friction dampingpromoting region (1000) bringing a portion of two surfaces of the closedinternal void (700) into contact within the friction damping promotingregion (1000) thereby further increasing the damping capability. In afurther embodiment, while a portion of two surfaces of the closedinternal void (700) are brought into contact, the gas remains in fluidcommunication across opposite sides of the deformed friction dampingpromoting region (1000), which may be accomplished by a channel, orchannels, in one or both of the contact surfaces. One such embodiment isshown in FIGS. 50A and 50B wherein the friction damping promoting region(1000) incorporates cooperating sidewall features that are brought intocooperation by the rolling step. For instance, the friction dampingpromoting region (1000) has a first sidewall cooperating feature (1010),which in some embodiments is a first sidewall apex (1012), and a secondsidewall cooperating feature (1020), which in some embodiments is asecond sidewall apex (1022). In the illustrated embodiment, prior todeformation of the void (700), as seen in FIG. 50A, the first sidewallapex (1012) is located across from, and in between, two second sidewallapexes (1022). Upon completion of the rolling step, the void (700) iscompressed and elongated to a state such as that seen in FIG. 50B, atwhich point a portion of two surfaces of the closed internal void (700)into contact within the friction damping promoting region (1000).

In still a further embodiment, extraordinary hardness may be achievedusing a PVD process, including but not limited to EB-PVD, arc-PVD, andsputtering, to apply a separate erosion-resistant damping coating (16)or a separate erosion-resistant coating with minimal damping attributessuch as a composite ceramic material to increases the hardness of thecoated substrate (100) to a Vickers hardness of at least 500 HV, seen inFIG. 3, onto the face-centered cubic ferromagnetic damping coating (10).One multilayered titanium nitride embodiment (TiN/Ti or TiN/TiCN orTiN/CrN), or nanocomposite layer of TiSiCN, achieves a Vickers hardnessof at least 1000 HV, and a further embodiment achieves a Vickershardness of at least 1500 HV. In the embodiments in which a carbidematerial is mixed in with the face-centered cubic damping powder, thepowder composition of the face-centered cubic ferromagnetic dampingpowder material and carbide material may be varied from 2:1 up to 20:1(weight %) depending on the desired hardness and/or erosion capability.In some embodiment in which a separate erosion-resistant damping coatingis created, an erosion-resistant damping powder is directed at theface-centered cubic ferromagnetic damping foil (100), analogous tocoating (10), identified as element #14 in the illustrated multi-layerembodiments, at an application velocity of at least 300 meters/secondusing an erosion-resistant damping coating carrier gas at anerosion-resistant damping coating application pressure such that atleast a portion of the erosion-resistant damping powder bonds to theface-centered cubic ferromagnetic damping coating (10) to create thecoated substrate (100).

In some embodiments the face-centered cubic ferromagnetic damping foil(600) has a Vickers hardness of less than 300 HV, while theerosion-resistant damping coating contains a carbide material andincreases the hardness of the coated foil to a Vickers hardness of atleast 350 HV. In this embodiment the softer face-centered cubicferromagnetic damping foil (600) layer significantly suppresses bladevibration and improves interface adhesion. The combination of a harderosion-resistant damping coating and a soft interior face-centeredcubic ferromagnetic damping foil provides the ability to withstand veryhigh stress and fatigue which therefore can act as a damage barrier toprevent cracks from penetrated into the substrate and to arrest cracksinitiated from the substrate. In one foil embodiment the face-centeredcubic damping material is selected from the group consisting of Co—Nibased face-centered cubic compositions, Co—Mn based face-centered cubiccompositions, and Fe—Mn based face-centered cubic compositions.

Multiple test beams were coated with the face-centered cubic dampingcoating (10) using the EB-PVD method to develop the data contained inthe figures. In fact multiple specimens of varying sizes were coatedusing the EB-PVD method and tested. The thickness of the face-centeredcubic ferromagnetic damping coating (10) on the test specimens wasapproximately 0.002-0.005 inches.

The cold spray process embodiment, the HVOF process embodiment, and theEB-PVD process embodiment produce a face-centered cubic ferromagneticdamping coating (10) with a low residual stress. In this HVOF embodimentthe low residual stress includes at least a tensile quenching stresscomponent and a compressive peening stress component. The tensilequenching stress component is contributed by the cooling and contractionof the at least partially molten face-centered cubic ferromagneticdamping coating powder on the surface (24) of the substrate (20). On theother hand, the compressive peening stress component is induced by theat least partially molten face-centered cubic ferromagnetic dampingcoating powder impacting the surface (24) of the substrate (20), orcoating (10), at high velocity causing a slight plastic deformation ofthe substrate (20) or coating (10). It has been appreciated that bycarefully controlling the application temperature and the applicationvelocity of the face-centered cubic ferromagnetic damping coatingpowder, the compressive peening stress component may be increased andthe tensile quenching stress component may be decreased. As a result,the face-centered cubic ferromagnetic damping coating (10) of the HVOFembodiment may have a low residual stress, where the compressive peeningstress component and the tensile quenching stress component effectivelycancel, or balance, one another to provide an approximately balancedcoating residual stress.

The cold spray process embodiment, the HVOF process embodiment, and theEB-PVD process embodiment provide the ability to apply a face-centeredferromagnetic damping coating (10) on a surface (24) of a substrate (20)that achieves high damping without having to subject the coatedsubstrate (100) to a high temperature annealing process, such asannealing at an annealing temperature of above 700° C. for an annealingperiod of longer than 30 minutes, followed by a controlled furnacecooling. The high damping is due in part to the face-centered cubicferromagnetic damping coating's (10) low residual stress, which isbelieved to create a substantially smaller amount of obstacles (i.e.,pinning sites) that hinder the movement of the magnetic domain wallswithin the ferromagnetic damping coating (10). Applicant has found thata residual stress within a range of ±50 MPa (with positive valuesrepresenting a tensile residual stress and negative values representinga compressive residual stress) allows a high level of damping in theface-centered cubic ferromagnetic damping coating (10). As used herein,the phrases “balanced coating residual stress” and “low residual stress”refer to a residual stress of the coating (10) within a range of ±50MPa. As a result of the low residual stress, geometrically complexstructural components, such as gas turbine components as seen in FIG. 4,may be damped with a face-centered cubic ferromagnetic damping coating(10) without suffering the drawbacks associated with the hightemperature annealing process. In a particular HVOF embodiment, the atleast partially molten face-centered cubic ferromagnetic damping coatingpowder is directed at the substrate at an application temperature of atleast 800° C. and at an application velocity of at least 450 meters persecond. These application parameters provide a delicate balance betweenthe thermal and kinetic energy imparted upon the face-centeredferromagnetic damping coating powder to obtain a low residual stresswithin the ±50 MPa range to achieve a high level of high strain dampingfrom the face-centered cubic ferromagnetic damping coating (10).

In one embodiment the method to increase the damping of a substrate (20)having a substrate thickness (22) comprises the steps of (a) creating aface-centered cubic damping powder having an average particle size of5-100 micrometers; and (b) directing the damping powder at a surface(24) of the substrate (20) at an application velocity of at least 300meters/second using a carrier gas at an application pressure such thatat least a portion of the damping powder bonds to the surface (24) ofthe substrate (20) to create a face-centered cubic ferromagnetic dampingcoating (10) on the surface (24) of the substrate (20), resulting in acoated substrate (100). In this embodiment the face-centered cubicferromagnetic damping coating (10) has a coating thickness (12) of about1% to about 30% of the substrate thickness (22), and in one embodimentthe substrate (20) is preferably coated on each side with each sidehaving a coating thickness (12) of 5-14% of the substrate thickness(22).

At this point it is important to introduce the concept of aface-centered cubic ferromagnetic damping material test beam to assistin defining the damping attributes of the invention. The face-centeredcubic ferromagnetic damping material test beam is specifically definedas a tapered beam and is made entirely from the face-centered cubicferromagnetic damping material; specifically a cast test beam of thedimensions shown in FIGS. 26-27. Introduction of the face-centered cubicferromagnetic damping material test beam is due to the complexity of thestress/strain induced energy dissipation damping mechanism of thedamping materials and the need to introduce an explicit test procedurethat is reliable and easily repeated. For example, one skilled in theart can easily identify the composition of a damping coating with commonlaboratory equipment and cast a test beam to a specified size, which canthen be used in a standardized test procedure to determine the dampingcapabilities of the coating.

For instance, the experiments (vibration runs) performed in developingFIGS. 6 & 7 were conducted on a Unholtz-Dickie 6,000 lb electro-dynamicshaker. The system is set up such that the tests are controlled by a PCwhich has Unholtz-Dickie control software installed. The software hasmany functions for different tests of interest, including sine sweeptest and a resonant dwell test, as well as a manual mode in which theuser is responsible for control. There are two primary instruments to beused in collecting data for the tests; namely strain gages and a laservibrometer system (Ploytec laser sensor head and Polytec vibrometercontroller).

The face-centered cubic ferromagnetic damping material test beam, in thecase of FIG. 7, or for comparison purposes a similarly dimensioned testbeam formed of body-centered cubic ferromagnetic damping material, inthe case of FIG. 6, was cantilever clamped with two clamping blocks on acylindrical fixture (diameter is 10 inches and 6.5 inches high) mountedon the top of the shaker head. The two clamping blocks having dimensionsof 2″×5.5″×0.25″ and 2″×5.5″×1.5″ inches (each has two outside sideholes and a center hole) were used to clamp the test beams. Threespecimen clamping bolts were carefully regulated to minimize specimenslippage, with 125-150 ft-lb applied on the two 0.75 in outer bolts andat 50-75 ft-lb on the central 0.375 inch bolt.

The test beam tip response velocity (v) at a resonant frequency (f) wasmeasured the laser vibrometer system and then covered to the tipdisplacement (d) via the known relationship d=v/(2π f). Then a standardfinite element analysis, using the software package ANSYS, was conductedon the tapered beams to calculate the maximum element strain with thecorresponding tip displacement measured from the laser head.

The graph illustrated in FIG. 7 shows the results of an experimentconducted at room temperature on a face-centered cubic ferromagneticdamping material test beam made entirely of a Co—Ni embodiment of theface-centered cubic ferromagnetic damping material. The vibrationdamping was depicted graphically in terms of the first mode test beamsystem loss factor (η) versus max strain (ε) as shown in FIG. 7. Thesystem loss factor was calculated using the half-power bandwidth method.

With continued reference to FIG. 7, one embodiment the face-centeredcubic ferromagnetic damping material test beam has a first mode testbeam system loss factor of at least 0.010 when the strain amplitude is500-2000 micro-strain, while an even further embodiment has a first modetest beam system loss factor of at least 0.015 when the strain amplitudeis above 1000 micro-strain. A still further embodiment has a first modetest beam system loss factor that is at least 0.020 where the strainamplitude is greater than 1250 micro-strain. An even further high strainembodiment has a first mode test beam system loss factor of at least0.020 when the strain amplitude is above 1500 micro-strain.Additionally, the damping properties of the face-centered cubicferromagnetic damping material may be characterized by the strainamplitude at the point of the maximum first mode test beam systemfactor. Thus, in one embodiment the face-centered cubic ferromagneticdamping material test beam has a maximum first mode test beam systemfactor occurs where the strain amplitude is greater than 250micro-strain, which is a significant improvement over the body-centeredcubic ferromagnetic damping material test beam illustrated in FIG. 6. Infact, in another embodiment the face-centered cubic ferromagneticdamping material test beam has a maximum first mode test beam systemloss factor occurs where the strain amplitude is greater than 500micro-strain, while an even further embodiment has a maximum where thestrain amplitude is greater than 1000 micro-strain. Achieving maximumdamping performance above 1000 micro-strain is particularly beneficialin high speed rotating turbines.

Additionally, many applications that benefit from damping coatingsparticularly benefit from predicable damping characteristics over a widestrain range. As such, a further embodiment is characterized by a firstmode test beam system loss factor that is greater than 0.010 throughouta consistent strain range wherein the consistent strain range isspecifically defined any continuous range of strain that is at least 250micro-strain from the lower end of the range to the upper end of therange, and the consistent strain range is above the level of 500micro-strain. Further the a first mode test beam system loss factorpreferably remains constant or increases through the consistent strainrange; in other words, it is preferably that the first mode test beamsystem loss factor does not have any increases followed by a decrease invalue as the strain increases because such variations create equipmentdesign difficulties. In one embodiment the first mode test beam systemloss factor varies by no more than twenty-five percent throughout theconsistent strain range. For example, in one such embodiment the localloss factor is greater than 0.010 throughout a consistent strain rangethat stretches from 750-1000 micro-strain and varies by no more thantwenty-five percent throughout the range of 750-1000 micro-strain, asillustrated in FIG. 7. Additional examples include the range of 250-500micro-strain and between the range of 500-750 micro-strain.

In another embodiment the consistent strain range is expanded to anyrange of at least 500 micro-strain above the level of 500 micro-strainand the variation of first mode test beam system loss factor is expandedonly from twenty-five percent to fifty percent. For example, in one suchembodiment the first mode test beam system loss factor is greater than0.010 throughout a consistent strain range that stretches from 500-1000micro-strain and varies by no more than fifty percent throughout therange of 500-1000 micro-strain. An additional example range seen in FIG.7 includes the range of 250-750 micro-strain.

Such a predictable first mode test beam system loss factor throughout aconsistent strain range is particularly desirable and offers excellentpredictability for the designers of equipment subject to undesirablevibrations. Further, a drawback with only using a ferromagnetic dampingcoating that is governed by either of the high and low strain coatingsis that there will be a strain regime were the damping is weak. Forexample, the body-centered cubic ferromagnetic damping coating of FIG. 6has strong damping, i.e. high first mode test beam system loss factors,only at low strain (50-100 micro-strain). If the strain is higher than amodest level of 200-300 micro-strain then the damping level is mostlysaturated to the baseline level. On the other hand, for a high straindamping coating, the high damping occurs only at high strain. If thestrain level is lower than 150 micro-strain then there less damping inthe high strain than there would be for the low strain damping coating.Instead of accepting a trade-off between high damping in one strainregime and low damping in another strain regime, the presentface-centered cubic ferromagnetic damping materials, coatings, andmethods can achieve a highly damped system for low and high strains asshown in FIG. 7.

While the above disclosure describes the damping capabilities affordedby the face-centered cubic ferromagnetic damping materials, coatings,and methods with reference to the face-centered cubic ferromagneticdamping material test beam and its associated first mode test beamsystem loss factors for convenience and simplicity, one skilled in theart will appreciate that the damping capabilities may also be expressedin terms of a local loss factor, seen in FIG. 14, and/or a coated beamsystem loss factor, as seen in 8-13, 15-25, and 30-45, and/or a testbeam system loss factor, as seen in FIGS. 6-7.

As one skilled in the art will recognize, damping is stress or straindependent which means the damping in the coating is a function of thestrain field (and hence, stress field). In order to make damping be afunction of strain we need a mechanism to vary local damping with localstrain values. For that, the local damping models/formulations of thebody-centered cubic (BCC) low strain damping coating and theface-centered (FCC) high strain damping coating deposited by a coldspray process, an electron beam physical vapor deposition (EB-PVD)process, and a HVOF process have been determined via an integratedanalytical and experimental procedure. A local damping formulation as afunction of local strain level was established by using a cubic localdamping function versus local strain as a baseline for comparison withexperimental data in finite element runs. The results of the finiteelement harmonic frequency sweep runs at known levels of strainamplitude were compared with the actual experimental results and theratio of the damping values between finite element predictions andexperimental data. Therefore, the stresses are extracted from finiteelement analysis and used to update the damping model in a loop. Everyfinite element in the coating has its own damping value based on thedamping model. Finally, an iterative procedure based on the convergenceof element stresses accomplished a converged local dampingfunction/model. The results of the finite element runs along with thedamping functions for several coating configurations are shown in theFIG. 14.

The concept of a face-centered cubic ferromagnetic damping material testbeam to assist in defining the damping attributes of the invention waspreviously introduced. At this point it is helpful to introduce anotherconcept to further aide in characterizing embodiments of the invention,namely a face-centered cubic ferromagnetic damping coating coated beam,or “FCC coated beam” for short. The FCC coated beam is specificallydefined as a flat beam of the dimensions illustrated in FIG. 25, unlessnoted otherwise. Introduction of the FCC coated beam is due to thecomplexity of the stress/strain induced energy dissipation dampingmechanism of the damping materials and the need to introduce an explicittest procedure that is reliable and easily repeated, plus it enables oneto define damping characteristics after undergoing an annealing process,which was not possible with the previously defined cast face-centeredcubic ferromagnetic damping material test beam. For example, one skilledin the art can easily identify the composition of a damping coating withcommon laboratory equipment and then create a FCC coated beam byapplying the face-centered cubic ferromagnetic damping coating to thestandardized beam of FIG. 25 using one of the application techniqueembodiments disclosed herein. A standardized test procedure can then beused on the FCC coated beam to determine the damping capabilities of thecoating. Unless noted otherwise the flat beam of FIG. 25 is Ti—6Al—4Vwith a uniform thickness of 0.063 inches and is coated on both sideswith the face-centered cubic ferromagnetic damping material,specifically a Co—Ni embodiment, to a thickness of 0.0035-0.0075 incheson each side, thereby producing a coated substrate (100). Theface-centered cubic ferromagnetic damping coating (10) may be appliedusing one of the low residual stress processes described herein.

The experiments (vibration runs) were conducted on a Unholtz-Dickie6,000 lb electro-dynamic shaker. The system is set up such that thetests are controlled by a PC which has an Unholtz-Dickie controlsoftware installed. The software has many functions for different testsof interest, including sine sweep test and a resonant dwell test as wellas a manual mode in which the user is responsible for control. Therewere two primary instruments to be used in taking data for the tests:strain gages and a laser vibrometer system (Ploytec laser sensor headand Polytec vibrometer controller). The FCC coated beam was clamped withtwo clamping blocks on a cylindrical fixture (diameter is 10 inches and6.5 inches high) mounted on the top of the shaker head. The two clampingblocks with dimension 2″×5.5″×0.25″ and 2″×5.5″×1.5″ (each has twooutside side holes and a center hole) were used to clamp the beam. Threespecimen clamping bolts were carefully regulated to minimize specimenslippage, with 125-150 ft-lb applied on the two 0.75 in outer bolts andat 75-100 ft-lb on the central 0.5 inch bolt. Tests were conducted usinga piezoelectric control accelerometer positioned immediately behind thespecimen clamping block. The beam tip response velocity (v) at aresonant frequency (f) was measured the laser vibrometer system and thencovered to the tip displacement (d) via equation d=v/(2π f). Then astandard finite element analysis using the software package ANSYS wasconducted of the beam to calculate the maximum element strain whichcorresponding the tip displacement measured from the laser head. Themaximum element strain was also confirmed with the calculation from thebeam theory.

The uncoated beams were first checked for damages or cracks using dyeand fault finder. If there are no damages already present the beams,then the natural frequencies and damping loss factor of the uncoatedbeams were measured by conducting the vibration experiments underharmonic excitation in 2^(nd), 3^(rd), and 4^(th) bending modes. Thedamping loss factor was calculated using the half-power bandwidth (BW)and resonant dwell (RD) methods (Ref. Granick, N. and Stern, J. E.“Material Damping of Aluminum by Resonance-Dwell Technique”, Shock andVibration Bulletin, Vol. 34, No. 5, pp. 177-195. 1966). The uncoatedbeams test results were used as baseline data for comparisons with thetest results of the FCC coated beams.

FIGS. 15-17 illustrate the coated beam system loss factor for Ti—6Al—4Vspecimens having a uniform thickness of 0.063 inches. The graphsillustrate the test results of two uncoated beam system loss factor inthe 2^(nd), 3^(rd), and 4^(th) modes; and the coated beam system lossfactor for three 0.063″ thick Ti—6Al—4V FCC coated beams in the 2^(nd),3^(rd), and 4^(th) modes, one coated via the HVOF application embodimentand two coated with the EB-PVD application embodiment. Each coated testbeam was coated on both sides with the face-centered cubic ferromagneticdamping material, specifically a Co—Ni embodiment, to a thickness of0.0035-0.0075 inches on each side. Each coated beam system loss factorwas at least 0.005, and increasing, at 500 micro-strain, for the 2^(nd),3^(rd), and 4^(th) modes, whether an HVOF embodiment or an EB-PVDembodiment. Further, each coated beam system loss factor was at least0.0075, and increasing, at 1000 micro-strain, for the 2^(nd) mode,whether an HVOF embodiment or an EB-PVD embodiment.

FIGS. 8-13, and 18-22 illustrate the coated beam system loss factor forTi—6Al—4V specimens having a uniform thickness of 0.063 inches, when thecoating was applied using a cold spray embodiment. FIG. 12 illustratethe test results of one uncoated beam system loss factor in the 2^(nd)mode; the coated beam system loss factor for two 0.063″ thick Ti—6Al—4VFCC coated beams in the 2^(nd) mode; and the coated beam system lossfactor for one 0.063″ thick Ti—6Al—4V FCC coated beams in the 2^(nd)mode after being subjected to a low temperature annealing processcomprising heating the coated substrate (100) to a temperature of 600°Fahrenheit for 2.5 hours, while FIG. 13 illustrates the same using theresonance dwell method (RD). Likewise, FIG. 10 illustrate the testresults of one uncoated beam system loss factor in the 3^(rd) mode; thecoated beam system loss factor for two 0.063″ thick Ti—6Al—4V FCC coatedbeams in the 3^(rd) mode; and the coated beam system loss factor for one0.063″ thick Ti—6Al—4V FCC coated beams in the 3^(rd) mode after beingsubjected to a low temperature annealing process comprising heating thecoated substrate (100) to a temperature of 600° Fahrenheit for 2.5hours, while FIG. 11 illustrates the same using the resonance dwellmethod (RD). Additionally, FIG. 8 illustrate the test results of oneuncoated beam system loss factor in the 4^(th) mode; the coated beamsystem loss factor for two 0.063″ thick Ti—6Al—4V FCC coated beams inthe 4^(th) mode; and the coated beam system loss factor for one 0.063″thick Ti—6Al—4V FCC coated beams in the 4^(th) mode after beingsubjected to a low temperature annealing process comprising heating thecoated substrate (100) to a temperature of 600° Fahrenheit for 2.5hours, while FIG. 9 illustrates the same using the resonance dwellmethod (RD). FIG. 10 illustrates the coated beam system loss factor fora 0.063″ thick Ti—6Al—4V FCC coated beams in the 3^(rd) mode; and thecoated beam system loss factor for one 0.063″ thick Ti—6Al—4V FCC coatedbeams in the 3rd mode after being subjected to a low temperatureannealing process comprising heating the coated substrate (100) to atemperature of 600° Fahrenheit for 2.5 hours, while FIG. 11 illustratesthe same using the resonance dwell method (RD).

Each coated test beam was coated on both sides with the face-centeredcubic ferromagnetic damping material, specifically a Co—Ni embodiment,to a thickness of 0.0035-0.0075 inches on each side. Each coated beamsystem loss factor was at least 0.005, and increasing, at 500micro-strain, for the 2^(nd) mode. Further, each coated beam system lossfactor was at least 0.0075, and increasing, at 1000 micro-strain, forthe 2^(nd) and 3^(rd) modes. As shown in FIGS. 12 and 10, even the lowresidual stress face-centered cubic ferromagnetic damping coating (10)applied via the cold spray process exhibited improved damping propertiesafter being subjected to a low temperature annealing process. In factafter the low temperature annealing process the 2^(nd) and 3^(rd) modecoated beam system loss factors increased to at least 0.014 at 500micro-strain; and at least 0.014 for the entire range of 500-1000micro-strain.

Additionally, a series of experiments were conducted on the FCC coatedbeams at three of temperature levels (room, 500° F., & 650° F.) forcharacterizing and identifying the FCC damping coating effectiveness atelevated temperatures, as seen in FIGS. 28-31 for Ti—6Al—4V coated testbeams using a dual process including a first 0.002″ thick EB-PVD coatinglayer applied at 350° C. and a second 0.002″ thick EB-PVD coating layerapplied at 500° C.; FIGS. 32-35 for stainless steel coated test beamsusing a single step process coating a single 0.005″ thick EB-PVD coatinglayer at 500° C.; FIGS. 36-39 for Ti—6Al—4V coated test beams using asingle step process coating a single 0.004″ thick EB-PVD coating layerat 350° C.; and lastly FIGS. 40-43 for Inconel coated test beams using adual process including a first 0.002″ thick EB-PVD coating layer appliedat 350° C. and a second 0.002″ thick EB-PVD coating layer applied at500° C.

Using the same testing procedure the dynamic characteristics (naturalfrequency, damping coated beam system loss factor, and maximum strain)of the FCC coated beam were accomplished. Tests at 500° F. & 650° F.were conducted by placing a heating chamber over the specimen andmounting fixture. The chamber is heated by two 900 watt ceramic plateheaters mounted on the interior sides of box. The heating chamber is arectangular box with outside dimensions 26″×15″×16″, with bottom cut tofit in the beam fixture blocks.

Comparing the single step embodiment of Ti—6Al—4V coated test beamsusing a single step process coating a single 0.004″ thick EB-PVD coatinglayer at 350° C. of FIGS. 36-39 with the dual step embodiment ofTi—6Al—4V coated test beams using a dual process including a first0.002″ thick EB-PVD coating layer applied at 350° C. and a second 0.002″thick EB-PVD coating layer applied at 500° C. reveals interesting hightemperature damping benefits afforded by the dual process embodiment.The dual step embodiment not only improves the quality of theface-centered cubic ferromagnetic damping coating but it also improvesthe speed of the process, reduces the likelihood of fatigue issues, andincreases the test beam system loss factor, particularly in hightemperature environments as illustrated by the 650° F. test data of FIG.28 versus that of FIG. 36. In fact, in one dual step embodiment thesecond mode coated beam system loss factor is at least 0.010 at 500micro-strain and at least 0.020 at 1000 micro-strain, when tested at650° F. In another embodiment the high temperature second mode coatedbeam system loss factor data has a slope of greater than 0.00001, whentested at 650° F.; while another embodiment has a high temperaturesecond mode coated beam system loss factor data has a slope of greaterthan 0.000015, when tested at 650° F.; and an even further embodimenthas a high temperature second mode coated beam system loss factor datahas a slope of greater than 0.00002.

Similarly, in another dual step embodiment the second mode coated beamsystem loss factor is at least 0.005 at 500 micro-strain and at least0.010 at 1000 micro-strain, when tested at 500° F. In another embodimentthe high temperature second mode coated beam system loss factor data hasa slope of greater than 0.000005, when tested at 500° F.; while anotherembodiment has a high temperature second mode coated beam system lossfactor data has a slope of greater than 0.00001, when tested at 500° F.Additionally, another dual step embodiment the second mode coated beamsystem loss factor is at least 0.005 at 500 micro-strain and at least0.008 at 1000 micro-strain, when tested at room temperature. In anotherembodiment the second mode coated beam system loss factor data has aslope of greater than 0.000005, when tested at room temperature; whileanother embodiment has a high temperature second mode coated beam systemloss factor data has a slope of greater than 0.00001, when tested atroom temperature.

The dual process EB-PVD coating embodiment is a way to control the grainsize of the face-centered cubic ferromagnetic damping coating (10). Thisis important because a coating with a relatively small grain sizeproduces lower strain damping, while a coating with relatively largergrain size produces higher strain damping. Therefore creating aface-centered cubic ferromagnetic damping coating (10) that has at leasta small grain size layer and a separate larger grain size layer producesdesirable damping characteristics throughout a wide strain range. Thus,in one embodiment a first EB-PVD face-centered cubic ferromagneticdamping coating layer is applied to a substrate maintained at a firstlayer temperature of 275° C.-350° C., and a second EB-PVD face-centeredcubic ferromagnetic damping coating layer is applied to the substratewhile maintaining it at a second layer temperature that is at least 25°C. greater than the first layer temperature, thereby providing a minimumdisparity of grain size, and thus strain damping characteristics. In afurther embodiment the grain size disparity is increased by having thesecond layer temperature at least 50° C. greater than the first layertemperature, while an even further embodiment has the second layertemperature at least 100° C. greater than the first layer temperature.Yet a further embodiment has a second layer temperature that is at least20% greater than the first layer temperature; and another embodiment hasa second layer temperature that is at least 40% greater than the firstlayer temperature, and even further a second layer temperature that is40%-100% greater than the first layer temperature. One skilled in theart will appreciate that in one embodiment the different temperaturesmay be achieved by adjusting the distance between the substrate and thevapor source.

A comparison of FIG. 36 and FIG. 15 illustrates the shift in dampingcapabilities when the application temperature of the face-centered cubicferromagnetic damping coating (10) is varied. FIG. 36 illustrates thesecond mode coated beam system loss factor of a Ti—Al—4V coated beamembodiment with the face-centered cubic ferromagnetic damping coatingapplied to the beam at 350° C., whereas FIG. 15 illustrates the secondmode coated beam system loss factor of a Ti—Al—4V coated beamembodiment, a slightly different size, with the face-centered cubicferromagnetic damping coating applied to the beam at 500° C. Comparingthe diamonds of FIG. 15 with the squares of FIG. 36 it is easy to seethat at 500 micro-strain level the second mode coated beam system lossfactor of FIG. 36 is approximately 0.004 when applied at 350° C.,whereas at the 500 micro-strain level the second mode coated beam systemloss factor of FIG. 15 is approximately 0.008 when applied at 500° C.Likewise at 1000 micro-strain the second mode coated beam system lossfactor of FIG. 36 is approximately 0.006 when applied at 350° C.,whereas at the 1000 micro-strain level the second mode coated beamsystem loss factor of FIG. 15 is approximately 0.015 when applied at500° C. Thus the test results on coated beams indicate that lowtemperature EB-PVD process embodiments (<350° C.) usually produces smallgrain size in the face-centered cubic ferromagnetic damping coating (10)which in turn leads to a significant increase of their damping capacityat low strain. However, the damping capacity at high strain decreasesapproximately 25% in maximum strain level in comparison with a highertemperature EB-PVD process embodiment (>500° C.). This behavior isdetermined to be contributed from the change of the mechanism ofvibratory energy dissipation associated with the domain walls movement.Therefore, by controlling the substrate temperature from 275-550° C.during the EB-PVD process, predetermined damping characteristics can beachieved with respect to desired strain regions or vibration modes.

An even further embodiment incorporates three or more distinct layers ofthe face-centered cubic ferromagnetic damping coating (10), each appliedat a different temperature to achieve a desired damping profile across awide strain range, and/or target damping in specific modes, via thecontrol of coating's grain size in each layer. Thus, in one embodiment afirst PVD face-centered cubic ferromagnetic damping coating layer isapplied to a substrate maintained at a first layer temperature of 275°C.-350° C., a second PVD face-centered cubic ferromagnetic dampingcoating layer is applied to the substrate while maintaining it at asecond layer temperature that is at least 25° C. greater than the firstlayer temperature, and a third PVD face-centered cubic ferromagneticdamping coating layer is applied to the substrate while maintaining itat a third layer temperature that is at least 25° C. greater than thesecond layer temperature, thereby providing a minimum disparity of grainsize, and thus strain damping characteristics. In a further embodimentthe grain size disparity is increased by having the second layertemperature at least 50° C. greater than the first layer temperature andthe third layer temperature at least 50° C. greater than the secondlayer temperature, while an even further embodiment has the second layertemperature at least 100° C. greater than the first layer temperatureand the third layer temperature at least 100° C. greater than the secondlayer temperature. Yet a further embodiment has a third layertemperature that is at least 20% greater than the second layertemperature; and another embodiment has a third layer temperature thatis at least 40% greater than the second layer temperature, and an evenfurther embodiment has a third layer temperature that is 40%-100%greater than the second layer temperature.

In another embodiment variable grain size, and thus damping properties,is achieved in a single layer of the face-centered cubic ferromagneticdamping coating (10) by controlling different areas of the substrate atdifferent temperatures during the coating process. In many applicationsthat benefit from damping coatings the weight of the coating isimportant. One way of controlling the weight added to the substrate isto accomplish several goals within a single layer of the face-centeredcubic ferromagnetic damping coating (10). This may be accomplished bymaintaining different regions of the substrate at different temperaturesduring the coating process by a heat sink in contact with the substrate.The heat sink may be an external heat sink in contact with a particularportion of the substrate, or may be an internal heat sink designed intothe substrate, such as one designed to receive a cooling medium.Conversely, the maintenance of different regions of the substrate atdifferent temperatures may be accomplished with localized heating of thesubstrate rather than localized cooling. The localized heating may beachieved via an external heat source or an internal heat source.Regardless of whether local cooling or heating is used, a firstsubstrate region is maintained at a first region temperature during thecoating process and a second substrate region is maintained at a secondregion temperature during the coating process. In one embodiment thesecond region temperature that is at least 25° C. greater than the firstregion temperature, thereby providing a minimum disparity of grain sizewithin a single layer of face-centered cubic ferromagnetic dampingcoating (10). In a further embodiment the grain size disparity isincreased by having the second region temperature at least 50° C.greater than the first region temperature, while an even furtherembodiment has the second region temperature at least 100° C. greaterthan the first region temperature. Yet a further embodiment has a secondregion temperature that is at least 20% greater than the first regiontemperature; and another embodiment has a second region temperature thatis at least 40% greater than the first region temperature, and an evenfurther embodiment has a second region temperature that is 40%-100%greater than the first region temperature. On example where suchembodiments may be desirable is in a rotating blade application in whichgreater high strain damping is desired toward the tip of the blade.Alternative embodiments may be designed to have different dampingproperties toward the leading edge of a rotating blade.

Alternatively the single layer may be applied in a step-wise process toeliminate the need for localized heating or cooling. For instance, thesubstrate may be masked to expose the first region to the face-centeredcubic ferromagnetic damping coating process at a first temperature, thenthe substrate may be masked to expose the second region to theface-centered cubic ferromagnetic damping coating process at a secondtemperature. The first region and the second region need not come incontact with one another, but may. Thus, in this embodiment thesubstrate ends up with a single thickness of face-centered cubicferromagnetic damping coating (10) having different grain sizes anddamping attributes in light of the different temperature relationshipspreviously disclosed but not repeated here for brevity.

Much like the Ti—6Al—4V coated test beams benefited from a dual processcoating, so to did the Inconel coated test beams illustrated in FIGS.40-43, while the stainless steel test beams performed well when thelower temperature 350° C. EB-PVD coating step was skipped and the entirecoating was applied in one step at the elevated temperature of 500° C.Applying the lower temperature 350° C. EB-PVD coating step to thetitanium and Inconel substrates provided a protective layer to shield atleast a portion of the substrate from the higher temperature 500° C.EB-PVD coating step, thereby reducing potential spalling and fatigueissues. The dual step embodiment of ˜0.064″ thick Inconel coated testbeams using a dual process including a first 0.002″ thick EB-PVD coatinglayer applied at 350° C. and a second 0.002″ thick EB-PVD coating layerapplied at 500° C. reveals interesting high temperature damping benefitsafforded by the dual process embodiment. The dual step embodiment notonly improves the quality of the face-centered cubic ferromagneticdamping coating but it also improves the speed of the process, reducesthe likelihood of fatigue issues, and increases the test beam systemloss factor, particularly in high temperature environments asillustrated by the 650° F. test data of FIG. 40. In fact, in one dualstep embodiment the second mode coated beam system loss factor is atleast 0.006 at 500 micro-strain and at least 0.012 at 1000 micro-strain,when tested at 650° F. In another embodiment the high temperature secondmode coated beam system loss factor data has a slope of greater than0.00001, when tested at 650° F.; while another embodiment has a hightemperature second mode coated beam system loss factor data has a slopeof greater than 0.000015, when tested at 650° F.; and an even furtherembodiment has a high temperature second mode coated beam system lossfactor data has a slope of greater than 0.00002.

Similarly ˜0.079″ thick stainless steel coated test beams coated usingthe present face-centered cubic ferromagnetic damping coating (10) usingthe disclosed methods also exhibits excellent high temperature dampingcharacteristics, even without the use of a dual step coating process.The stainless steel coated test beams of FIGS. 32-35 were coated in asingle step applied at 500° C. using an EB-PVD embodiment to a coatingthickness of ˜0.005″ on each side of the test beam. This hightemperature application improves the quality of the face-centered cubicferromagnetic damping coating and also improves the speed of theprocess, and may increase the test beam system loss factor in hightemperature environments. In fact, in one embodiment the second modecoated beam system loss factor is at least 0.006 at 500 micro-strain andat least 0.012 at 1000 micro-strain, when tested at 650° F. In anotherembodiment the high temperature second mode coated beam system lossfactor data has a slope of greater than 0.00001, when tested at 650° F.;while another embodiment has a high temperature second mode coated beamsystem loss factor data has a slope of greater than 0.000015, whentested at 650° F.; and an even further embodiment has a high temperaturesecond mode coated beam system loss factor data has a slope of greaterthan 0.00002.

The vibration damping associated with each coated beams is depictedgraphically in terms of the system loss factor (η) versus max strain(ε). Each coated beam was cantilever clamped on a high power vibrationshaker. Frequency response functions for each coated beam were measuredutilizing an accelerometer and a laser-vibrometer for measuring thevelocity or displacement of a point on the coated beam. In many of thefigures including “(BW)” in the title the system loss factor wascalculated using the half-power bandwidth method, hence the abbreviation“(BW)” in the titles. According to the half-power bandwidth method, areference point on the frequency response function of √{square root over(2)}/1, or 0.707, of the maximum amplitude is chosen. This amplitudecrosses the frequency response function at two different frequencies,with the difference between these two different frequencies being thehalf-power band. The relationship between the half-power band and thefrequency of the maximum amplitude (i.e., resonant frequency) is themeasurement of the system loss factor (η), which can be seen by thefollowing equation:

$\eta \approx \frac{{half}\text{-}{power}\mspace{14mu}{band}}{{resonant}\mspace{14mu}{frequency}}$

The strain on each coated beam was determined via finite element methodto correlate the displacement of the coated beam at a point to thestrain at the root of the coated beam. The actual displacement at aspecific point was then calculated from the measured velocity at thatpoint while vibrating in a resonant mode. The following equation wasused to calculate the displacement:d=v(2πf)where “v” is the measured velocity of the coated beam at a point and “f”is the measured resonant frequency.

The strain at any point on the coated beam can then be determined fromthe calculated displacement of the coated beam and the mode shape. Thecoated beams were excited in cantilever bending modes (i.e., secondbending mode, third bending mode, and fourth bending mode) and the datais referred to in terms of the max strain amplitude in the mode shape,which occurs at the root of the specimen. Using the finite elementmethod, it is possible to find a conversion factor between observeddisplacement and root strain.

Regardless of the application technique, the face-centered cubicferromagnetic damping coating (10) is applied as one or more thinlayers. Applicant has found that applying the face-centered cubicferromagnetic damping coating (10) having a coating thickness (12) ofabout 1% to about 30% of the substrate thickness (22) allows theferromagnetic damping coating (10) to provide high damping at highstrain levels without having an adverse effect on the substrate (20).For example, when the substrate (20) comprises a component of a gasturbine, a coating thickness (12) that is too large can decrease theefficiency and operability of the gas turbine component. In oneembodiment, the face-centered cubic ferromagnetic damping coating (10)may be deposited one side of the substrate (20); while in otherembodiments, the face-centered ferromagnetic damping coating (10) may bedeposited on more than one side of the substrate (20). As used herein,coating thickness (12) refers to the total thickness of theface-centered ferromagnetic damping coating (10) applied to thesubstrate (20).

While the above disclosure describes the damping capabilities affordedby the face-centered cubic ferromagnetic damping materials, coatings,and methods with reference to the face-centered cubic ferromagneticdamping material test beam and its associated first mode test beamsystem loss factors for simplicity, as well as a face-centered cubicferromagnetic damping coated test beam and its associated second modecoated beam system loss factor, one skilled in the art will appreciatethat the damping capabilities may also be expressed in terms of a localloss factor, seen in FIG. 14. With reference again to FIG. 14, the localloss factor produced by the present method is unique in that it producesa face-centered cubic ferromagnetic damping coating having (a) a highlocal loss factor when a strain amplitude is 500-2000 micro-strain,and/or (b) a maximum local loss factor that occurs when the strainamplitude is greater than 250 micro-strain. In the past ferromagneticdamping coatings have generally been low strain coatings, seen in FIG.14, which quickly reach their maximum local loss factor at a very lowstrain value, often less than 0.0001. Utilizing the unique face-centeredcubic ferromagnetic damping coating materials and processes herein themaximum local loss factor can be achieved where it is needed most,namely in high strain values.

For example, the “low strain coating” illustrated in FIG. 14 is abody-centered cubic (BCC) low strain ferromagnetic damping coatingcharacterized by a maximum local loss factor of approximately 0.0385 ata local strain of less than 100 micro-strain, and the local loss factorquickly falls to less than 0.010 by the 400 micro-strain level. The linelabeled “cold spray high strain coating pre heat treated test data”illustrates an embodiment of the present invention which produced alocal loss factor of at least 0.010 when the strain amplitude isanywhere in the range of 500-2000 micro-strain. Conversely, the priorart “low strain coating” shown in the figure illustrates that the localloss factor has already reached a maximum and is far less than 0.010 inthe range of 500-2000 micro-strain. In fact, FIG. 14 illustrates anembodiment in which the line labeled “cold spray high strain coating preheat treated test data” illustrates that the present invention producesa local loss factor of the coated substrate (100) of at least 0.013 whenthe strain amplitude is 500-2000 micro-strain. Further, the line labeled“cold spray high strain coating pre heat treated test data” demonstratesa maximum local loss factor occurs where the strain amplitude is greaterthan 500 micro-strain. Conversely, the prior art “low strain coating”shown in the figure illustrates that the local loss factor reaches amaximum local loss factor at less than 100 micro-strain.

In another embodiment the maximum local loss factor occurs where thestrain amplitude is greater than 1500 micro-strain, again as illustratedby the “cold spray high strain coating pre heat treated test data” lineof FIG. 14. Achieving a maximum local loss factor above 1500micro-strain is particularly beneficial in high speed rotating turbines.

A further embodiment is characterized by a local loss factor that isgreater than 0.010 throughout a consistent strain range wherein theconsistent strain range is specifically defined any continuous range ofstrain that is at least 250 micro-strain from the lower end of the rangeto the upper end of the range, and the consistent strain range is abovethe level of 500 micro-strain. In one embodiment the local loss factorvaries by no more than twenty-five percent throughout the consistentstrain range. For example, in one embodiment the local loss factor isgreater than 0.010 throughout a consistent strain range that stretchesfrom 750-1000 micro-strain and varies by no more than twenty-fivepercent throughout the range of 750-1000 micro-strain, as illustrated bythe “cold spray high strain coating pre-heat treated test data”embodiment of FIG. 14. Additional examples include the “cold spray highstrain coating pre-heat treated test data” embodiment between the rangeof 250-500 micro-strain, between the range of 500-750 micro-strain, andbetween the range of 1000-1250 micro-strain; the “EB-PVD High StrainCoating” embodiment between the range of 500-750 micro-strain, andbetween the range of 750-1000 micro-strain; and the “cold spray highstrain coating heat treated” embodiment between the range of 250-500micro-strain, between the range of 500-750 micro-strain, between therange of 750-1000 micro-strain, between the range of 1000-1250micro-strain, between 1250-1500 micro-strain, between 1500-1750micro-strain, and between 1750-2000 micro-strain.

In another embodiment the consistent strain range is expanded to anyrange of at least 500 micro-strain above the level of 500 micro-strainand the variation of local loss factor is expanded only from twenty-fivepercent to fifty percent. For example, in one such embodiment the localloss factor is greater than 0.010 throughout a consistent strain rangethat stretches from 500-1000 micro-strain and varies by no more thanfifty percent throughout the range of 500-1000 micro-strain. Additionalexamples include the “cold spray high strain coating pre-heat treatedtest data” embodiment between the range of 250-750 micro-strain, andbetween the range of 750-1250 micro-strain; the “EB-PVD High StrainCoating” embodiment between the range of 500-1000 micro-strain; and the“cold spray high strain coating heat treated” embodiment between therange of 250-750 micro-strain, between the range of 500-1000micro-strain, and between the range of 750-1250 micro-strain.

In another embodiment the consistent strain range is expanded to anyrange of at least 1000 micro-strain above the level of 500 micro-strainand the variation of local loss factor is no more than fifty percent.For example, one such embodiment has a local loss factor that is greaterthan 0.010 throughout a consistent strain range that stretches from250-1250 micro-strain and varies by no more than fifty percentthroughout the range of 250-1250 micro-strain.

Such a predictable local loss factor throughout a consistent strainrange is particularly desirable and offers excellent predictability forthe designers of equipment subject to undesirable vibrations. Further, adrawback with only using a single ferromagnetic damping coating that isgoverned by either of the high and low strain coatings is that therewill be a strain regime were the damping is weak. For a coating withdamping characteristics that are described by the low strain coating thestrong damping occurs only at low strains (50-100 micro-strain). If thestrain is higher than a modest level of 200-300 micro-strain then thedamping level is mostly saturated to the baseline level. On the otherhand, for a high strain damping coating, the high damping occurs only athigh strains. If the strain level is lower than 150 micro-strain thenthere less damping in the high strain than there would be for the lowstrain damping coating. Instead of accepting a trade-off between highdamping in one strain regime and low damping in another strain regime,the present face-centered cubic ferromagnetic damping coating and methodcan achieve a highly damped system for low and high strains as shown viathe integrated experimental and analytical approach illustrated in FIG.14.

The previously disclosed method may also include a low temperatureannealing process comprising heating the coated substrate (100) to atemperature less than 800 degrees Celsius thereby producing an annealedcoated substrate having a local loss factor of at least 0.020 when thestrain amplitude is 500-2000 micro-strain, and the maximum damping lossfactor occurs where the strain amplitude is greater than 1000micro-strain. In an even further embodiment the local loss factor of atleast 0.030 when the strain amplitude is 500-2000 micro-strain, and themaximum damping loss factor occurs where the strain amplitude is greaterthan 1000 micro-strain. This embodiment is also illustrated with thetest data of FIG. 14 and the line labeled “cold spray high straincoating heat treated.” Thus, in this embodiment the low temperatureannealing process more than doubles the local loss factor over the “coldspray high strain coating pre heat treated test data” line for thevalues of local strain in the range of 500 micro-strain to 1750micro-strain, however it also increases the slope of the local lossfactor. One particular low temperature annealing embodiment utilizes aprocess that heats the coated substrate (100) to a temperature of atleast 300 degrees Celsius for an annealing period of less than 4 hours.

It is well known that when titanium and titanium alloys are subjected toa high temperature heat treatment, an oxygen-enriched layer, known asalpha case, will form on the surface of the titanium or titanium alloy.The alpha case is generally much harder and more brittle than thetitanium or titanium alloy. For example, the alpha case layer generallyhas a Vicker's hardness number ranging from about 500 to 600, while thebulk hardness (i.e., the interior hardness) of the titanium or titaniumalloy ranges from about 200 to 350. Moreover, a titanium or titaniumalloy component that has been coated may still be susceptible to theformation of an alpha case layer. This can occur when oxygen diffusesthrough the coating layer and into the titanium or titanium alloysubstrate microstructure just below the interface created between thecoating layer and the surface of the titanium or titanium alloysubstrate.

For many applications, an alpha case layer is highly undesirable becauseit has reduced fatigue resistance and tends to create a series ofmicrocracks, which can reduce the metal's performance and cause failure.Generally, before the heat treated titanium or titanium alloy isutilized, the layer of alpha case must be removed by a chemical etchingprocess or by mechanical means.

Unless noted otherwise, the local loss factors, the test beam systemloss factors, and the coated beam system loss factors discussed hereinare achieved without the need to perform a high temperature annealingprocess. By avoiding a high temperature annealing process, thelikelihood of developing a very hard and brittle alpha case layer at thecoating-substrate interface is substantially reduced. As a result, inone embodiment, a hardness of the titanium based substrate (20) at thecoating-substrate interface may be within 25% of the bulk hardness(i.e., the interior hardness) of the titanium based substrate (20). Inanother embodiment, the hardness of the titanium based substrate (20) atthe coating-substrate interface is within 5% of the bulk hardness of thetitanium based substrate (20). The proximity of the hardness valuesindicate that very little, if any, alpha case has formed on the titaniumbased substrate (20). As a result, the turbine component comprising atitanium based substrate (20) is able to be damped by application of aface-centered cubic ferromagnetic damping coating (10) without having toundergo a high temperature annealing process, and thereby substantiallyavoids the formation of unwanted alpha case that can lead to earlycomponent failure.

The dependence of the damping capability, in terms of loss factor η (orQ⁻¹), on vibratory strain amplitude of the coated beam and blade hasbeen determined experimentally. The performance and effectiveness of thehigh strain damping were evaluated and demonstrated by the experimentalresults from a Ti—6Al—4V beam and a titanium blade coated with a thinlayer of face-centered cubic ferromagnetic damping coating (10),specifically a high strain face-centered cubic ferromagnetic Co—Ni baseddamping coating, which was subjected to various exciting forces at roomtemperature. The face-centered cubic ferromagnetic damping coating (10)may have a coating thickness (12) of about 1% to about 30% of thesubstrate thickness (22).

As shown in FIGS. 8-13, in one embodiment the coated substrate (100) hasa coated beam system loss factor of approximately 0.005 at strainamplitude of 150-3000 micro-strain without annealing, which increases toapproximately 0.015 with a low temperature annealing process at 600° F.for 2.5 hours. FIGS. 8 and 9 illustrate the 4^(th) mode with FIG. 8calculating the coated beam system loss factor via the half-powerfrequency bandwidth method (BW), while FIG. 9 calculates the coated beamsystem loss factor via the resonance dwell method (RD). Likewise, FIGS.10 and 11 illustrate the 3rd mode with FIG. 10 calculating the coatedbeam system loss factor via the half-power frequency bandwidth method(BW), while FIG. 11 calculates the coated beam system loss factor viathe resonance dwell method (RD). Similarly, FIGS. 12 and 13 illustratethe 2nd mode with FIG. 12 calculating the coated beam system loss factorvia the half-power frequency bandwidth method (BW), while FIG. 13calculates the coated beam system loss factor via the resonance dwellmethod (RD). The system loss factor of the uncoated beam is around0.0003, which is about 1/17 of the beam coated with the face-centeredcubic ferromagnetic damping coating, and is about 1/50 of the beamcoated with the face-centered cubic ferromagnetic damping coating thathas been subjected to the low temperature annealing step. Theface-centered cubic ferromagnetic damping coating may provide evenhigher system loss factors for strain levels greater than 2000micro-strain. The face-centered cubic ferromagnetic damping coatingproduces a system loss factor, or the energy dissipation density percycle of the coating layer, that is largely independent of the vibratoryfrequency of coated substrates. This frequency independent featureallows this damping system to be capable of enhancing dampingsignificantly at almost all the vibration modes of coated turbine bladesincluding high order stripe modes in particular.

With reference to FIGS. 8-9, the coated beam system loss factor for the4^(th) mode of a test beam coated with the present face-centered cubicferromagnetic damping coating produces (a) a coated beam system lossfactor that is greater than 0.002 when the strain is greater than 150micro-strain, and (b) a maximum coated beam system loss factor thatoccurs when the strain amplitude is greater than 200 micro-strain. In afurther low temperature heat treated embodiment in which the specimen isheated to 600° F. for 2.5 hours, the present face-centered cubicferromagnetic damping coating produces (a) a coated beam system lossfactor that is greater than 0.010 when the strain is greater than 100micro-strain, and (b) a maximum coated beam system loss factor thatoccurs when the strain amplitude is greater than 100 micro-strain.Similarly, with reference to FIGS. 10-11, the coated beam system lossfactor for the 3rd mode of a test beam coated with the presentface-centered cubic ferromagnetic damping coating produces (a) a coatedbeam system loss factor that is greater than 0.002 when the strain isgreater than 150 micro-strain, and (b) a maximum coated beam system lossfactor that occurs when the strain amplitude is greater than 200micro-strain. In a further low temperature heat treated embodiment inwhich the specimen is heated to 600° F. for 2.5 hours, the presentface-centered cubic ferromagnetic damping coating produces (a) a coatedbeam system loss factor that is greater than 0.010 when the strain isgreater than 100 micro-strain, and (b) a maximum coated beam system lossfactor that occurs when the strain amplitude is greater than 100micro-strain. Similarly, with reference to FIGS. 12-13, the coated beamsystem loss factor for the 2^(nd) mode of a test beam coated with thepresent face-centered cubic ferromagnetic damping coating produces (a) acoated beam system loss factor that is greater than 0.002 when thestrain is greater than 150 micro-strain, and (b) a maximum coated beamsystem loss factor that occurs when the strain amplitude is greater than200 micro-strain. In a further low temperature heat treated embodimentin which the specimen is heated to 600° F. for 2.5 hours, the presentface-centered cubic ferromagnetic damping coating produces (a) a coatedbeam system loss factor that is greater than 0.010 when the strain isgreater than 100 micro-strain, and (b) a maximum coated beam system lossfactor that occurs when the strain amplitude is greater than 100micro-strain.

While FIGS. 8-13 illustrated specific embodiments in which theface-centered cubic ferromagnetic damping coatings were applied using acold spray embodiment, FIGS. 15-17 illustrate similar system loss factordata for embodiments in which the face-centered cubic ferromagneticdamping coatings was applied using an EB-PVD process embodiment and aHVOF process embodiment, thereby illustrating similar high straindamping capabilities of the face-centered cubic ferromagnetic dampingcoating when applied in the partially molten state of the HVOF processor as a vapor via the EB-PVD process. As seen in FIG. 15, the systemloss factor for the 2^(nd) mode of a test beam coated with the presentface-centered cubic ferromagnetic damping coating produces (a) a coatedbeam system loss factor that is greater than 0.002 when the strain isgreater than 150 micro-strain, and (b) a maximum coated beam system lossfactor that occurs when the strain amplitude is greater than 200micro-strain, whether applied using the EB-PVD process or the HVOFprocess. As seen in FIG. 16, the system loss factor for the 3^(rd) modeof a test beam coated with the present face-centered cubic ferromagneticdamping coating produces (a) a coated beam system loss factor that isgreater than 0.002 when the strain is greater than 150 micro-strain, and(b) a maximum coated beam system loss factor that occurs when the strainamplitude is greater than 200 micro-strain, whether applied using theEB-PVD process or the HVOF process. Further, as seen in FIG. 25, thesystem loss factor for the 4^(th) mode of a test beam coated with thepresent face-centered cubic ferromagnetic damping coating produces (a) acoated beam system loss factor that is greater than 0.002 when thestrain is greater than 150 micro-strain, and (b) a maximum coated beamsystem loss factor that occurs when the strain amplitude is greater than200 micro-strain, whether applied using the EB-PVD process or the HVOFprocess. FIGS. 15-17 each contains two sets of data labeled as “EB-PVDCoated (FCC)” which simply correspond to data from two different testspecimens which is why the data points are virtually identical.

FIG. 7 illustrates the test results in the damping capability in termsof test beam system loss factor (η or Q⁻¹) with respect to strainamplitude for an embodiment of the present face-centered cubicferromagnetic damping coating material. For typical body-centered cubic(BCC) low strain damping coating materials, similar to the test resultsshown in FIG. 6, the test beam system loss factor increases rapidly asthe forcing accelerations increases and reaches a stationary value asthe maximum strain of the beam approaching 80 to 100 micro-strain andthen decreases relatively quickly at higher strain regions. On the otherhand, the present face-centered cubic ferromagnetic damping coatingmaterial produces a test beam system loss factor, without heattreatment, that increases rapidly as the forcing accelerations increasesand reaches a stationary value as the maximum strain of the coated beamapproaching 250 micro-strain and then remains in the high damping regionto about 1200 micro-strain, after which the test beam system loss factorincreases rapidly at higher strain regions. Further, as disclosedelsewhere, embodiments incorporating a low temperature annealing stepfurther increase the coated beam system loss factors.

As previously mentioned, the present methods produces a coating with lowresidual stress. In one particular embodiment the face-centered cubicferromagnetic damping coating (10) has a low residual stress within arange of ±50 MPa without the coated substrate ever being subjected to anannealing temperature of above 700° C. for an annealing period of longerthan 30 minutes. In another embodiment the majority of the residualstress present in the face-centered cubic ferromagnetic damping coating(10) is compressive residual stress. In an even further embodimentproduced by the solid state cold spray application method there is notensile residual stress present in the face-centered cubic ferromagneticdamping coating (10). However, in light of the residual stressesintroduced during rolling, an embodiment of the face-centered cubicdamping material foil (600) is heat treated at an annealing temperatureabove 700° C. for an annealing period of at least 30 minutes to obtainresidual stress within a range of ±50 MPa, while a further heat treatedembodiment achieves residual stress within a range of ±25 MPa.

The cold spray process and HVOF processes disclosed herein produce manygreat advantages in creating a low residual stress high strainface-centered cubic ferromagnetic damping coating (10), however theprocesses tend to produce a coating that is relatively rough. Thereforeanother embodiment incorporates a polishing step wherein majority of thesurface area of the coated substrate (100) has a surface roughness ofless than 0.635 μm for Ra. An even further embodiment polishes theface-centered cubic ferromagnetic damping coating (10) so that majorityof the surface area has a surface roughness of less than 0.127 μm forRa, less than 0.254 μm for Rq, and less than 0.762 μm for Rt.

One particular embodiment produces a coated substrate (100) has aVickers hardness of at least 250 HV. An even further embodiment has acoated substrate (100) with a Vickers hardness of at least 350 HV, andyet another embodiment the hardness of the coated substrate (100) is atleast 10% greater than the hardness of the substrate (20). Such hardnessembodiments may be achieved by introducing a carbide material such assilicon carbide (SiC) in the face-centered cubic damping powder, orincluding a step of applying a separate erosion-resistant dampingcoating (16) or a separate erosion-resistant coating, seen in FIG. 3,onto the face-centered cubic ferromagnetic damping coating (10),identified as element #14 in the illustrated multi-layer embodiments, tocreate the coated substrate (100). Such an erosion-resistant dampingcoating may achieve high erosion and wear resistance along withincreased stiffness, strength, hardness, improved corrosion resistance,and high temperature oxidation resistance. Other hard metal carbidessuch as tungsten carbine and boron carbide may also be used. In themultiple layer embodiment one particular subembodiment is designed sothat the face-centered cubic ferromagnetic damping coating (14) has aVickers hardness of less than 300 HV, while the erosion-resistantdamping coating (16) contains a carbide material and increases thehardness of the coated substrate (100) to a Vickers hardness of at least350 HV. In this embodiment the softer face-centered cubic ferromagneticdamping coating (14) layer significantly suppresses blade vibration andimproves interface adhesion. The combination of a hard erosion-resistantdamping coating (16) and a soft interior face-centered cubicferromagnetic damping coating (14) provides the ability to withstandvery high stress and fatigue which therefore can act as a damage barrierto prevent cracks from penetrated into the substrate and to arrestcracks initiated from the substrate.

Extraordinary hardness may be achieved using a PVD process, includingbut not limited to EB-PVD, arc-PVD, and sputtering, to apply a separateerosion-resistant damping coating (16) or a separate erosion-resistantcoating with minimal damping attributes such as a composite ceramicmaterial to increases the hardness of the coated substrate (100) to aVickers hardness of at least 500 HV, seen in FIG. 3, onto theface-centered cubic ferromagnetic damping coating (10). One multilayeredtitanium nitride embodiment (TiN/Ti or TiN/TiCN or TiN/CrN), ornanocomposite layer of TiSiCN, achieves a Vickers hardness of at least1000 HV, and in embodiment achieves a Vickers hardness of at least 1500HV.

In the embodiments in which a carbide material is mixed in with theface-centered cubic damping powder, the powder composition of theface-centered cubic ferromagnetic damping powder material and carbidematerial may be varied from 2:1 up to 20:1 (weight %) depending on thedesired hardness and/or erosion capability. In the embodiment in which aseparate erosion-resistant damping coating is created, anerosion-resistant damping powder is directed at the face-centered cubicferromagnetic damping coating (10), identified as element #14 in theillustrated multi-layer embodiments, at an application velocity of atleast 300 meters/second using an erosion-resistant damping coatingcarrier gas at an erosion-resistant damping coating application pressuresuch that at least a portion of the erosion-resistant damping powderbonds to the face-centered cubic ferromagnetic damping coating (10) tocreate the coated substrate (100).

FIGS. 18-23 show the test results of Ti—6Al—4V beams coated with a twolayer face-centered cubic ferromagnetic damping coating (10) having afirst face-centered cubic ferromagnetic damping coating (14), as seen inFIG. 3, applied to the substrate (20) via a cold spray process, and anerosion-resistant damping coating (16) applied to the firstface-centered cubic ferromagnetic damping coating (14) via a cold sprayprocess. The erosion-resistant damping coating (16) layer includes aface-centered cubic damping coating powder mixed with silicon carbidepowder. The comparison of damping test results of coated, coated andheat treated, and uncoated beams illustrates that the coated beam systemloss factor is increased approximately ten-fold which indicates thatvibratory stresses are reduced on the order of 80% compared to theuncoated beam. Such multi-layer embodiments of the face-centered cubicferromagnetic damping coating (10) also produce a maximum coated beamsystem loss factor occurs where the strain amplitude is greater than 250micro-strain. Additionally, in some embodiments the coated substrate(100) has a coated beam system loss factor of at least 0.010 when thestrain amplitude is 500-2000 micro-strain. Upon review of FIGS. 18-23one skilled in the art will recognize the multi-layer embodiments of theface-centered cubic ferromagnetic damping coating (10) may also achieveany of the coated beam system to strain relationships that have beenpreviously disclosed, which will not be repeated again here for the sakeof brevity.

Lastly, one skilled in the art will appreciate that the presentinvention is not limited to the method of increasing the damping of thesubstrate (20), but includes the products produced.

Thus, the substrate (20) may comprise a turbine component, such as a fanblade, compressor blade, impeller, blisk, or integrally bladed rotor; asports implement; automotive component; or virtually any component thatsubjected to vibrations in use that are undesirable, just to name a few.The substrate (20) may be formed of virtually any metal including, butnot limited to, titanium, titanium-based alloys, steel alloys, nickel,nickel-based alloys, aluminum, and aluminum-based alloys. As usedherein, the term “turbine” may refer to gas turbines, steam turbines,water turbines, wind turbines, or any other type of turbine orcomponents thereof that experience vibrational stresses. Further, oneskilled in the art will recognize that although the experimentalexamples described throughout this disclosure repeatedly refer toEB-PVD, the present invention is not limited to EB-PVD and mayincorporate other physical vapor deposition (PVD) variants including,but not limited to, cathodic arc deposition, evaporative deposition,pulsed laser deposition, and sputter deposition, just to name a few.

Numerous alterations, modifications, and variations of the preferredembodiments disclosed herein will be apparent to those skilled in theart and they are all anticipated and contemplated to be within thespirit and scope of the method for applying a low residual stressface-centered cubic ferromagnetic damping coating, as claimed below. Forexample, although specific embodiments and examples have been describedin detail, those with skill in the art will understand that thepreceding embodiments and variations can be modified to incorporatevarious types of substitute and or additional or alternative processesand materials, relative arrangement of elements, and dimensionalconfigurations. Accordingly, even though only few variations of themethod are described herein, it is to be understood that the practice ofsuch additional modifications and variations and the equivalentsthereof, are within the spirit and scope of the method as defined in thefollowing claims.

I claim:
 1. A method to increase the damping of a substrate, comprising:a) creating a face-centered cubic damping material ingot comprising aface-centered cubic damping material, and having a ingot length, ingotwidth, and ingot thickness; b) rolling the face-centered cubic dampingmaterial ingot to create a face-centered cubic damping material foilhaving a foil grain size, foil length, foil width, foil thickness, andhardness; c) applying an erosion-resistant coating onto at least aportion of the face-centered cubic damping material foil, wherein theerosion-resistant coating increases the hardness to a Vickers hardnessof at least 350 HV, and wherein the step of applying theerosion-resistant coating includes the steps of: i) creating anerosion-resistant material ingot; ii) placing the erosion-resistantmaterial ingot and the face-centered cubic damping material foil in avacuum chamber; iii) heating the face-centered cubic damping materialfoil to an erosion-resistant layer application temperature; iv) formingan erosion-resistant layer vapor from the erosion-resistant materialingot within the vacuum chamber; and v) condensing the erosion-resistantlayer vapor on at least a portion of the face-centered cubic dampingmaterial foil to create the erosion-resistant coating of anerosion-resistant coated FCC damping material foil, wherein theerosion-resistant coating has an erosion-resistant coating thickness andan erosion-resistant coating grain size different than the foil grainsize; and d) applying a portion of the erosion-resistant coated FCCdamping material foil to the substrate; and e) wherein the step ofcreating the face-centered cubic damping material ingot includes the useof an additive manufacturing process to form at least one closedinternal void within the face-centered cubic damping material ingot,wherein the void has an initial void volume, an initial length, aninitial void width, and an initial void height, and the rolling processof creating the face-centered cubic damping material foil deforms atleast one aspect of the void producing a final void volume, a final voidlength, a final void width, and a final void height, wherein (a) thefinal void length is at least 2 times the initial void length, (b) thefinal void height is no more than 6% of the initial void height, and (c)the initial void height is at least 20% of the erosion-resistant coatingthickness.
 2. The method according to claim 1, wherein the foil lengthis at least 5 times the ingot length, and the foil thickness is lessthan 6% of the ingot thickness.
 3. The method according to claim 2,wherein the foil thickness is at least 0.5% of the ingot thickness, andthe erosion-resistant coating thickness is at least 20% of the foilthickness.
 4. The method according to claim 3, wherein theerosion-resistant coating thickness is no more than 125% of the foilthickness.
 5. The method according to claim 1, wherein (a) the finalvoid length is at least 4 times the initial void length, (b) the finalvoid height is at least 0.5% of the initial void height, (c) the initialvoid height is 50-5000% of the erosion-resistant coating thickness, and(d) the final void volume is at least 10% less than the initial voidvolume.
 6. The method according to claim 1, wherein the additivemanufacturing process is performed in a sealed environment containing agas, and the at least one closed internal void within the face-centeredcubic damping material ingot contains the gas at an initial pressure;wherein the rolling process of creating the face-centered cubic dampingmaterial foil deforms at least one aspect of the void producing thefinal void volume containing the gas at a final pressure that isdifferent from the initial pressure.
 7. The method according to claim 6,wherein the final pressure is at least 10% greater than the initialpressure.
 8. The method according to claim 6, wherein the step ofapplying a portion of the erosion-resistant coated FCC damping materialfoil to the substrate further including the step of first cutting anerosion-resistant coated FCC damping material foil pattern from theerosion-resistant coated FCC damping material foil, and then applyingthe erosion-resistant coated FCC damping material foil pattern to thesubstrate.
 9. The method according to claim 8, wherein theerosion-resistant coated FCC damping material foil pattern has a patternperimeter, and a portion of the pattern perimeter traverses at least aportion of the at least one closed internal void, and further includingthe step of sealing the void along the portion of the pattern perimeterthat traverses the void to provide a cutting path that will not releasethe gas from the void when cutting the erosion-resistant coated FCCdamping material foil pattern from the erosion-resistant coated FCCdamping material foil.
 10. The method according to claim 6, wherein theclosed internal void includes a friction damping promoting region, andwherein the rolling step deforms a portion of the friction dampingpromoting region bringing a portion of two surfaces of the closedinternal void into contact within the friction damping promoting region.11. The method according to claim 10, wherein the gas remains in fluidcommunication across opposite sides of the deformed friction dampingpromoting region.
 12. The method according to claim 1, wherein theinitial length, the initial void width, and the initial void height ofthe closed internal void are each less than 250 micron.
 13. The methodaccording to claim 12, wherein an initial shape of the closed internalvoid is a sphere.
 14. The method according to claim 1, wherein prior tothe rolling step the closed internal void is formed of smooth continuoussurfaces having local radiuses of curvature of at least 0.5 micron andis free of stress riser step discontinuities.
 15. The method accordingto claim 1, wherein the face-centered cubic damping material foil hasresidual stress within a range of ±50 MPa, and the erosion-resistantcoating increases the hardness to a Vickers hardness of at least 500 HV.16. The method according to claim 15, wherein the face-centered cubicdamping material foil has a Vickers hardness of less than 300 HV. 17.The method according to claim 1, wherein the face-centered cubic dampingmaterial is selected from the group consisting of Co—Ni basedface-centered cubic compositions, Co—Mn based face-centered cubiccompositions, and Fe—Mn based face-centered cubic compositions.
 18. Themethod according to claim 17, wherein the erosion-resistant coatingincludes at least one of TiN, TiCN, CrN, and TiSiCN.